Form / Format FF NPM 21 Page No.

: 1 of 2
Process FMEA ISSUE NO. 9 REV No: 02
PROCESS FMEA
Process Owner : Mr.Jay Kishan
FMEA No. KT7/FMEA/620
REV No: 01
Project Name: PROJ-Neolite -KT-09

Product Name: Wire Harness Assy (N 1510)

Part No : 120000007240 CFT Members: Mr. Ravinder Dhankar, Mr. Abdul Kareem, Mr. Sunil
Revision No.: Rev-4 Bhardwaj, Mr. Harishankar Tripathi, Mr. Kannan, Ms Kirtee,Mr Date(Revised): 03.05.2025
Date: 03.05.2025 Alok,Mr Jay kishan ,Mr Prakash ,Mr Abhishek ,Mr Lalit kumar .
Drawing No: HL-1510-034
KAYNES REPORT NO: Not Applicable
FMEA prepared by: Mr.Abhishek

Responsi Action Results

Occurrence

Detection
Potential Current Recommende bility & Actions

Severity

RPN No
Process Name or Potential Potential

Class
Cause(s)/Mech Current Process controls Process d Actions Target Taken
Function Requirements failure Effect(s) of

RPN
Occ

Det
Sev
anism Prevention controls ( Refer Note Completi
Mode failure on Date
Failure(s) Detection 1)

10.1 Proper packing as per During inward , Stores incharge

No proper Customer Transportation
packing instruction 6 check the packing condition of 2 IQC Report 6 72

x
Packing dissatisfaction /mishandling
each child part

10.Inward inspection
Wrong part Incoming material verification as
received from per Challan 2 IQC Report 5 20
supplier Refer KT7/SPWI/119
Slight
10.2 Accepted Label as per Wrong PDF
inconvenience to 2
x

part specification Label on part

operation

Misprinting in pdf Visual Verification as per Good receiving

2 5 20
label Invoice/Challan note

Slight Wrong quantity

wrong Incoming material verification as Goods receiving
10.3 Correct Quantity inconvenience to 2 received from 2 5 20
x

quantity per Challan note

operation supplier
 Refer WI QAM 09 Guidelines for
Damaged packaging damged IQC Report
7 Handling of Cable and Raw 2 5 70

x
components during transit ICT
Materials
A portion of the
production run
10.4 Damage free components
may have to be
scrapped
Moisture on Refer WI QAM 09 Guidelines for IQC Report
MSD level not
the 7 Handling of Cable and Raw 2 MSD Sticker on 5 70

x
available
component Materials the Spool

Wrong Make 100% of product Wrong make &

10.5 No wrong make and Customer Approved Make & IQC Report
and MPN may have to be 8 MPN uploaded in 1 5 80

x
MPN Inwarded MPN has uploaded in ERP
inwarded scrapped ERP

100% of
10.Inward inspection production run IQC accepted
Refer WI QAM 09 Guidelines for
10.6 No Mixup of confirming Mix up of may have to be Area identification sticker on parts
4 Handling of Cable and Raw 2 5 70
and non confirming material material reworked in not available Self checked by
Materials
station before it operator
is processed

Dimensional
results of the Specific inspection plan upload
100% of product Line get stopped
10.7 No wrong dimensional received items x in ERP for custome built part
may have to be 8 and OTD will 2 IQC Report 5 80
items are inwarded are not as per Balloning diagram for the
scrapped affect
the Customer inspection
drawings.

Note: The following Dimensions considered while identifying potential effect of failures:
a. Effect on Customer
b. Effect on KT
c. Statutory and Regulatory
d. Product safety
e. Personnel safety
SYMBOL LEVEL SEVERITY NO DOCUMENTS IMPACTED BY THIS FMEA(Applicable documents mark as √)

CRITICAL 9 & 10 CONTROL PLAN CTQ

NOTE:-SPECIAL CHARACTERISTICS IDENTIFICATION x SEVERE 6, 7 & 8 BOM OQC Checklist
NO SYMBOL LOW 1 T0 5 SPECIFIC WI PFC
Δ SAFETY 9 & 10 CONTROL PLAN CTQ

Rev. No. DESCRIPTION OF REVISIONS CARRIED OUT DATE Prepared Approved

0 Initial Release 12.10.2022 Prakash Lalit Kumar
1 Revised for Updated Drawing 03.05.2025 Abhishek Lalit Kumar

Approved By: (NPD Head)

Prepared By: (Executive - NPD) Reviewed By: (AM - QA) Reviewed By: (Supervisor/HOD-Prod.)
Sign:
Sign: Sign: Sign: Name: Mr Lalit Kumar
Name: Mr. ABHISHEK Name: Mr. ALOK Name: Mr.Jay Kishan Date: 03.05.2025
Date: 03.05.2025 Date: 03.05.2025 Date: 03.05.2025
 Form / Format FF NPM 21 Page No.: 1 of 2
Process FMEA ISSUE NO. 9 REV No: 02
PROCESS FMEA
Process Owner : Mr.Jay Kishan
FMEA No. KT7/FMEA/620
REV No: 01
Project Name: PROJ-Neolite -KT-09

Product Name: Wire Harness Assy (N 1510)

Part No : 120000007240 CFT Members: Mr. Ravinder Dhankar, Mr. Abdul Kareem,
Mr. Sunil Bhardwaj, Mr. Harishankar Tripathi, Mr. Kannan,
Revision No.: Rev-4 Date(Revised): 03.05.2025
Ms Kirtee,Mr Alok,Mr Jay kishan ,Mr Prakash ,Mr
Date: 03.05.2025 Abhishek ,Mr Lalit kumar .
Drawing No: HL-1510-034
KAYNES REPORT NO: Not Applicable
FMEA prepared by: Mr.Abhishek

Recommend
Responsibility &

Occurrence
ed Actions Action Results

Detection
Current Current

Severity

RPN No
Process Name or Potential Potential Target Actions

Class
Potential failure Process Process Completion Date Taken
Function Requirements Effect(s) of Cause(s)/Mecha

RPN
Occ

Det
Sev
Mode controls controls
failure nism Failure(s)
Prevention Detection
( Refer
Note 1)

Material binning as
Rack identification per the Rack
2 5'S Audit 6 24
not given identification
Slight FF QAM 26
20.1 Easy access of Access of material is not
inconvenience to 2
material adequate
operator
Maximum height
Maximum height not display boards
2 5'S Audit 6 24
followed available
FF QAM 26

Refer WI WHM 03
for MSD handling
MSD tag not
Refer WI QAM 09
available on the 2 6 72
Guidelines for MSD Audit
Component
20.Storage of Material Handling of Cable
and Raw Materials

100% of
20.2 Moisture free Moisture on the production run Dry chamber Temp. entry Dry Dry Chamber Log
6 2 5 60
monitoring not done chamber log book Book
x

storage component may have to be

reworked

Refer WI WHM 02
FIFO not followed for FIFO (color 2 6 72
Patrol Audit
coding)

Ambient Condition
Temperature and
of temperature and Temperature &
Humidity indicator 2 5 60
humidity not humidity chart
available
available
 ESD monitoring
unit available
100% of Refer Specific work
ESD generation on the production run ESD grounding not instruction ESD audit
20.3 ESD safe storage 6 2 6 72

x
component may have to be done KT7/SPWI/365
reworked Reaction plan for
ESD monitoring
unit

Every Shift and as

Comparison of
and when
Skill Level -L2 Minimum the Actual VS
operators are
Required
changed.

Note: The following Dimensions considered while identifying potential effect of failures:
a. Effect on Customer
b. Effect on KT
c. Statutory and Regulatory
d. Product safety
e. Personnel safety
SYMBOL LEVEL SEVERITY NO DOCUMENTS IMPACTED BY THIS FMEA(Applicable documents mark as √)

CRITICAL 9 & 10 CONTROL PLAN CTQ

NOTE:-SPECIAL CHARACTERISTICS IDENTIFICATION x SEVERE 6, 7 & 8 BOM OQC Checklist
NO SYMBOL LOW 1 T0 5 SPECIFIC WI PFC

Δ SAFETY 9 & 10 CONTROL PLAN CTQ

Rev. No. DESCRIPTION OF REVISIONS CARRIED OUT DATE Prepared Approved

0 Initial Release 12.10.2022 Prakash Lalit Kumar
1 Revised for Updated Drawing 03.05.2025 Abhishek Lalit Kumar

Approved By: (NPD Head)

Prepared By: ( Executive - NPD) Reviewed By: (AM - QA) Reviewed By: (Supervisor/HOD-Prod.)
Sign:
Sign: Sign: Sign: Name: Mr Lalit Kumar
Name: Mr. ABHISHEK Name: Mr. ALOK Name: Mr.Jay Kishan Date: 03.05.2025
Date: 03.05.2025 Date: 03.05.2025 Date: 03.05.2025
 Form / Format FF NPD 15 Page No.: 1 of 2
Process FMEA ISSUE NO. 8 REV No: 0

PROCESS FMEA

Process Owner Mr. Sunil

FMEA No. KT7/SPFMEA/124 Core team: 1. Mr. Parminder Singh
REV No: 5 2. Ms. Divya Shree Date: 23.05.2018
Project Name: IJL 3. Mr. Lalit Sharma
Product Name: K43H LED HL PRINT BASE ASSY 4. Mr. Sunil
Part No : 10009-8F011 5. Ms. Anitha
Revision No.: NA 6. Mr. Arif
Date: 15.05.2017 7. Mr .Kartik
Drawing No: A5272 8. Mr. Anmol Maheshwari
KAYNES REPORT NO: Not Applicable 9. Mr.Pawan
10. Mr. Arvind Gautam FMEA prepared by: Himanshu Verma
11. Mr. Govind Saini
12. Mr. Himanshu Verma
Responsi

Occurrence

Detection
bility & Action Results

Severity

RPN No
Potential Current Process Recommended

Class
Process Name or Potential failure Potential Effect(s) of Current Process Target Actions
Requirements Cause(s)/Mecha controls Actions
Completi
Function Mode failure controls Detection Taken

RPN
Occ
Sev

Det
nism Failure(s) Prevention (Refer note 1)
on Date

Refer KT7/SPWI/092
Afroz Separate
for rework guideline Separate (10.09.20 Rework table
with
Mixing Pb and Pb-free Mixing Pb and Pb-free Violation of Product Separate rework for solder wire Rework Report Rework table 16) identification
wire / soldering tool wire / soldering tool requirement
7 x
station not available Separate Rework
3 7 147 with
7 2 7 98
implemented
table for ROHS and identification
Non-ROHS

Refer WI QRP 12
Self check by Production
Guidelines for
Handling of PCB
Handling of PCBAs
2 operator 7 98
and Raw Materials

Refer WI PRP 30 for

Self check by Production
Manual Soldering of
operator
Component Damage Functional failure 7 x Wrong Tip Selection Through Hole 2 Rework Report
7 98
Components
& Parameter Chart

Refer WI PRP 39 for Self check by Production

No proper tool Rework and Repair operator
selection of SMD and TH
2 Rework Report
7 98
components

Job Set up verification

Overheating of Tip temperature
Delamination of PCB Functional failure 7 x
component PAD measurement
2 Rework Report 7 98

Refer WI PRP 30 for

Self check by Production
Manual Soldering of
operator
Wrong Tip Selection Through Hole 2 Rework Report
7 98
Soldering (As per IPC A Components
610 F Class3) & Parameter Chart

Solder Splash Functional/Intermitent failure 7 x

Support
PCBA shall be kept System Support
Anmol
No proper support at ESD mat Self check by Production required to system
system for PCBA Support Syatem to
3 operator
7 147 keep the PCBA
(30.09.2016
implemented
7 2 7 98
)
keep the PCBA on Rework at Rework
table

Job Set up verification

Wrong tip Tip temperature
tmperature measurement
2 Rework Report 7 98

330. Rework
Solder Ball Functional/Intermitent failure 7 x
Table cleaning has Cleaning kit & Cleaning kit
Self check by Production Anmol
No cleaning of to done before start Cleaning & Cleaning
Table & end of shift
3 operator 7 147 checklist (30.09.2016
checklist
7 2 7 98
)
Cleaning Kit required implemented

Page 5 of 39
 Responsi

Occurrence
330. Rework

Detection
bility & Action Results

Severity

RPN No
Potential Current Process Recommended

Class
Process Name or Potential failure Potential Effect(s) of Current Process Target Actions
Requirements Cause(s)/Mecha controls Actions
Function Mode failure controls Detection (Refer note 1) Completi Taken

RPN
Occ
Sev

Det
nism Failure(s) Prevention on Date

Job Set up verification

Set temperature is Tip temperature
Solder Short Functional failure 7 x
Wrong. measurement
2 Rework Report 7 98

Job Set up verification

Set temperature is Tip temperature
Pin Hole Latent Failure 5
Wrong. measurement
2 FSI 7 70

Area
Area
OK PCBA shall be Self check by Production Afroz Identification
Mixup of OK and NOT OK Input and Out put Area Identification Identification
processed for next
PCBA
Functional/Intermitent failure 7 x
area is not defined at Rework Stage
3 operator 7 147 for ease of (05.09.2016 for ease of 7 2 7 98
stage ) operation
operation
implemented

Mannual adjustment
Mannual CTQ required
No rework of PCBA of component prior Self check by Production CTQ required Anmol
Rework of PCBA done adjustment of at Pre-Reflow
prior to Reflow
prior to reflow soldering
Functional failure 7 x
component prior to
to Reflow soldering 3 operator 7 147 at Pre-Reflow (02.09.2016
stage
7 2 7 98
soldering is strictly stage )
Reflow soldering diplayed
probhihated

Action-1:
Separate QA
required to
execute the Mukta
Separate QA
rework Yadav
Refer KT7/SPWI/027 Self check by Production deployed at
activities (01.04.2017
Rework of components Rework done for the Lack of awareness for rework operator rework stage
as per defined guideline restricted components
Functional failure 7 x
of rework guidelines guidelines of SMD
4 Rework report
7 196 Action-2: )
Rework
7 2 7 98
Rework report Anmol
and TH components report format
format will be (01.04.2017
modified
modified by )
including sign
off at each
stage

Adjustable chairs
Adequate operating inadequate operating Adjustable chairs Self check by Production
posture of operation posture of operation
Functional/Intermittent failure 7 x
not available
available at work 2 operator
7 98
station

Refer defect
Defect handling
Rework to be perform No QA approval taken for handling procedure Rework Report
by QA approval rework
Functional/Intermittent failure 7 x procedure not
KT7/SPWI/029 for
2 7 98
available
Rework

Note: The following Dimensions considered while identifying potential effect of failures:
a. Effect on Customer
b. Effect on KT
c. Statutory and Regulatory
d. Product safety
e. Personnel safety

Rev No DESCRIPTION OF REVISIONS CARRIED OUT DATE Prepared (Exec -Engg) By Approved By
0 Initial Release 28.05.2017 Anmol Maheshwari Jnana Jyothi
1 ICT and Unit Level Testing Added 15.07.2017 Anmol Maheshwari Jnana Jyothi
2 Revised for Pre Launch 07.12.2017 Arvind Anmol
3 Released for Initial Supply Control 02.01.2018 Himanshu Verma Anmol Maheshwari
4 Revised for wire interchange of Cable 09.02.2018 Himanshu Verma Anmol Maheshwari
5 Revised for termination of ISC period 23.05.2018 Himanshu Verma Anmol Maheshwari

Prepared By: (Executive - NPD) Reviewed By: (Executive - QA) Reviewed By: (Supervisor/HOD-Prod.) Reviewed By: (Project Manager) Approved By: (Moderator)

Sign: Sign: Sign: Sign: Sign:

Name: Mr. Neeraj Saini Name: Mrs Mukta Yadav Name: Mr. Lalit Sharma Name: Mr . Mohan Prasad J Name: Mr. Anmol Maheshwari

Date: 08.08.2019 Date: 08.08.2019 Date: 08.08.2019 Date: 08.08.2019 Date: 08.08.2019

Note1: The intent of any recommended action is to reduce ranking of Severity ,Occurrence and Detection

Note 2: See annexure for specific requirements ( customer / card)

Page 6 of 39
 Responsi

Occurrence

Detection
bility & Action Results

Severity

RPN No
Potential Current Process Recommended

Class
Process Name or Potential failure Potential Effect(s) of Current Process Target Actions
Requirements Cause(s)/Mecha controls Actions
Function Mode failure controls Detection (Refer note 1) Completi Taken

RPN
Occ
Sev

Det
nism Failure(s) Prevention on Date

Note 3: Potential failure mode to be identified based onTGR/TGW, product recalls, product audits, field returns and repairs, customer complaints, scrap and rework.

Note 4:Manufacturing process design and development output shall focus on error prevention rather than detection by using poka-yoke methods.

Page 7 of 39
 Form / Format FF NPD 15 Page No.: 1 of 1
Process FMEA ISSUE NO. 8 REV No: 0

PROCESS FMEA
Process Owner Mr. Sunil
FMEA No. KT7/SPFMEA/124 Core team: 1. Mr. Pankaj Chandel
REV No: 0 2. Ms. Jnana Jyothi
Project Name: IJL 3. Mr. Lalit Sharma Date: 28.05.2017
Product Name: K43H LED HL PRINT BASE ASSY 4. Ms. Arpitha
Part No : 10009-8F011 5. Ms. Anitha
Revision No.: NA 6. Mr. Arif
Date: 15.05.2017 7. Mr. Anmol Maheshwari
Drawing No: NK-103 8. Mr. Rohit
KAYNES REPORT NO: Not Applicable 9. Mr. Sunil FMEA prepared by: Mr. Anmol Maheshwari
10. Mr. Afroz
Responsi

Occurrence

Detection
bility & Action Results

Severity

RPN No
Potential Potential Recommended

Class
Process Name or Potential failure Current Process Current Process Target Actions
Requirements Effect(s) of Cause(s)/Mecha Actions
Completi
Function Mode controls Prevention controls Detection Taken

RPN
Occ
Sev

Det
failure nism Failure(s) (Refer note 1)
on Date

Specific Work Instruction

No Flux residue in the 1. Aesthetic Improper method of Final Soldering
PCBA
Improper Cleaning
appearance
5
cleaning
for Spot cleaning 2
Inspection
7 70
KT7/SPWI/626

140. Spot Cleaning Movement

Movement of Anmol
Movement of ESD Specific Work Instruction of ESD
No movement of Intermitent Movement of ESD Final Soldering ESD brush to
brush towards outside
ESD brush defined Failure
5
Brush not defined
for Spot cleaning 2
Inspection
7 70 be define in
(05.09.20 brush to be 5 1 7 35
of PCBA KT7/SPWI/626 16) defined in
SPWI
SPWI

Note: The following Dimensions considered while identifying potential effect of failures:
a. Effect on Customer
b. Effect on KT
c. Statutory and Regulatory
d. Product safety
e. Personnel safety
DOCUMENTS IMPACTED BY THIS FMEA
SYMBOL LEVEL Ranking (Applicable documents mark as √)
NOTE:-SEVERITY
● CRITICAL 9 & 10 CONTROL PLAN CTQ
RANKING
x SEVERE 6,7 & 8 BOM OQC Checklist
NO SYMBOL LOW 1 T0 5 SPECIFIC WI PFC
Rev No DESCRIPTION OF REVISIONS CARRIED OUT DATE Prepared (Exec -Engg) By Approved By
0 Initial Release 28.05.2017 Anmol Maheshwari Jnana Jyothi
1 Revised for Prelaunch 20.01.2017 Anmol Maheshwari Jnana Jyothi
2 Revised for Production 15.03.2017 Anmol Maheshwari Jnana Jyothi
3 Revised for customer complaint screw loose 18.04.2017 Anmol Maheshwari Jnana Jyothi
4 PFMEA revised for more adequacy 25.04.2017 Anmol Maheshwari Jnana Jyothi
Note1: The intent of any recommended action is to reduce ranking of Severity ,Occurrence and Detection
Note 2: See annexure for specific requirements ( customer / card)

Page 8 of 39
 Form / Format FF NPD 15 Page No.: 1 of 2
Process FMEA ISSUE NO. 8 REV No: 0

PROCESS FMEA
Process Owner Mr. Sunil
FMEA No. KT7/SPFMEA/124 Core team: 1. Mr. Pankaj Chandel
REV No: 0 2. Ms. Jnana Jyothi
Project Name: IJL 3. Mr. Lalit Sharma Date: 28.05.2017
Product Name: K43H LED HL PRINT BASE ASSY 4. Ms. Arpitha
Part No : 10009-8F011 5. Ms. Anitha
Revision No.: NA 6. Mr. Arif
Date: 15.05.2017 7. Mr. Anmol Maheshwari
Drawing No: NK-103 8. Mr. Rohit
KAYNES REPORT NO: Not Applicable 9. Mr. Sunil FMEA prepared by: Mr. Anmol Maheshwari
10. Mr. Afroz
Responsi

Occurrence

Detection
bility & Action Results

Severity

RPN No
Potential Potential Recommended

Class
Process Name or Potential failure Current Process Current Process Actions Target Action
Requirements Effect(s) of Cause(s)/Mecha Completi
Function Mode controls Prevention controls Detection (Refer s

RPN
Occ
Sev

Det
failure nism Failure(s) note 1) on Date Taken

Specific Work Instruction

Excess application No proper control Final Soldering
of RTV
Fitment issue 3
on the Flow
for RTV 2
Inspection
7 42
Application-KT7/SPWI/627

Specific Work Instruction

Less application of No proper control Final Soldering
RTV
Latent Failure 5
on the flow.
for RTV 2
Inspection
7 70
Application-KT7/SPWI/627

With out RTV Glue Specific Wiork instruction

Availability of RTV Glue RTV Glue not Functional Failure 7 x boards mixed up for RTV Glue Application- 2 Final Soldering 7 98
at specified location applied with OK Boards. KT7/SPWI/627 Inspection

170. RTV Application 1. Poor Curing time Gloves Anmol(En Gloves

Spread of RTV Glue
2. Poor handling Specific work instruction cleaniness has cleanine
on electrical Final Soldering gg.)
Functional Failure 7 x before curing for RTV Glue application - 3 7 147 to ensured s 7 2 7 98
contact/adjacent
3. Cleaniness of KT7/SPWI/627
Inspection
before start of 05.09.20 defined
component
Gloves operation 16 in SPWI

1. Poor Curing time

Fixture
Spread of RTV Glue 2. Poor handling Specific work instruction Anmol(Eng Fixture
Final Soldering required for
on coarbon pad or Functional Failure 7 x before curing for RTV Glue application - 3
Inspection
7 147 RTV
g.) impleme 7 2 7 98
zebra connector 3. Fixture not used KT7/SPWI/627 25.04.2016 nted
Application
for RTV application

Specific work instruction

No bending of TH Bending of TH Size of Nozzle tip is Final Soldering
component component
Latent Failure 5
not adequate
for RTV Glue application - 2
Inspection
7 70
KT7/SPWI/627

No use of expired RTV LSL Register not LSL Register LSL Audit Report
Glue
Use of expired RTV Latent Failure 5
followed LSL Audit
2
Patrol Inspection
7 70

a. Effect on Customer
b. Effect on KT
c. Statutory and Regulatory
d. Product safety

Page 9 of 39
 Responsi

Occurrence

Detection
bility & Action Results

Severity

RPN No
Potential Potential Recommended

Class
Process Name or Potential failure Current Process Current Process Actions Target Action
Requirements Effect(s) of Cause(s)/Mecha Completi
Function Mode controls Prevention controls Detection (Refer s

RPN
Occ
Sev

Det
failure nism Failure(s) note 1) on Date Taken

e. Personnel safety
DOCUMENTS IMPACTED BY THIS FMEA
SYMBOL LEVEL Ranking (Applicable documents mark as √)
NOTE:-SEVERITY
● CRITICAL 9 & 10 CONTROL PLAN CTQ
RANKING
x SEVERE 6,7 & 8 BOM OQC Checklist
NO SYMBOL LOW 1 T0 5 SPECIFIC WI PFC
Rev No DESCRIPTION OF REVISIONS CARRIED OUT DATE Prepared (Exec -Engg) By Approved By
0 Initial Release 28.05.2017 Anmol Maheshwari Jnana Jyothi
1 Revised for Prelaunch 20.01.2017 Anmol Maheshwari Jnana Jyothi
2 Revised for Production 15.03.2017 Anmol Maheshwari Jnana Jyothi
3 Revised for customer complaint screw loose 18.04.2017 Anmol Maheshwari Jnana Jyothi
4 PFMEA revised for more adequacy 25.04.2017 Anmol Maheshwari Jnana Jyothi
Note1: The intent of any recommended action is to reduce ranking of Severity ,Occurrence and Detection
Note 2: See annexure for specific requirements ( customer / card)

Page 10 of 39
 Form / Format FF NPD 15 Page No.: 1 of 2
Process FMEA ISSUE NO. 8 REV No: 4

PROCESS FMEA

Process Owner Mr. Sunil

FMEA No. KT7/SPFMEA/180 Core team: 1. Mr. Ajay Tyagi
REV No: 0 2. Ms. Divya Shree Date(Orignal): 14.08.2020
Project Name: IJL(YTA) 3. Mr. Praveen Gautam
Product Name: YTA CLL A & B PCBA 4. Mr. Sunil
Part No : 10009/10029-7R02W 5. Ms. Anitha
Revision No.: b 6. Mr. Arif Date(Revised): 14.08.2020
Date: 29.06.2020 7. Mr .Kartik
Drawing No: A8939 8. Mr. Anmol Maheshwari
KAYNES REPORT NO: Not Applicable 9. Mr.Pawan
10. Mr. Sonu Yadav FMEA prepared by: Ravi Ranjan
11. Mr. Govind Saini
12. Mr. Om Prakash
Responsi

Occurrence

Detection
bility & Action Results

Severity

RPN No
Potential Potential Recommended

Class
Process Name or Potential failure Current Process Current Process Target Actions
Requirements Effect(s) of Cause(s)/Mecha Actions
Completi
Function Mode controls Prevention controls Detection Taken

RPN
Occ
Sev

Det
failure nism Failure(s) (Refer note 1)
on Date

190.1 NO
COMPONENT
MISSING
190.2 NO REVERSE
MOUNT
190.3 NO
COMPONENT LIFT Component Missing
190.4 NO WRONG Reverse mount
VALUE Component Lift
190.5 NO ASSEMBLY Wrong Value magnifier is not
OF DAMAGED Assy of damage using for Inspection
COMPONENTS Components Functional Untrained operator
190. Final Component 1. Refer Specific work Component Inspection
Inspection
190.6 NO INTERCHANGE OF failure/Traceabilit 7 x Guidelines or
instruction KT7/SPWI/1047
2
report(KT7/FCI/FSI/002)
7 98
INTERCHANGE OF CABLE y issues checking list not
2. Refer Specific work
CABLE Damage of cable available for
instruction KT7/SPWI/636
190.7 No Damage of No interchange of inspection
Cable barcode label
190.8 No Interchange No smudge or torn
of barcode Serial No. In off of barcode label
PCB A & B
190.9 No Smudge/torn
off of barcode
190.10 No missing of
Barcode

200.1 NO NON
SOLDER
200.2 NO BLOW/PIN
Non solder
HOLE
Blow/Pin hole
200.3 NO EXCESS
Excess solder
SOLDER
Less solder
200.4 NO LESS
Solder short Mix up of PCBA's in
SOLDER Soldering Inspection
200. Final soldering Solder ball the same tray 1. Refer Specific work
Inspection
200.5 NO SOLDER
Dry solder
Testing failure 7 x
Magnifier not used instruction KT7/SPWI/1047
2 report 7 98
SHORT (KT7/FCI/FSI/002)
Pad lift for inspection 2. Refer Specific work
200.6 NO SOLDER OQC
Component lift instruction KT7/SPWI/636
BALL
Solder Splash
200.7 NO DRY SOLDER
Spike solder
200.8 NO PAD LIFT
200.9 NO SOLDER
SPLASH
200.10 No Spike Solder

Page 11 of 39
 Responsi

Occurrence

Detection
bility & Action Results

Severity

RPN No
Potential Potential Recommended

Class
Process Name or Potential failure Current Process Current Process Target Actions
Requirements Effect(s) of Cause(s)/Mecha Actions
Completi
Function Mode controls Prevention controls Detection Taken

RPN
Occ
Sev

Det
failure nism Failure(s) (Refer note 1)
on Date

Note: The following Dimensions considered while identifying potential effect of failures:
a. Effect on Customer
b. Effect on KT
c. Statutory and Regulatory
d. Product safety
e. Personnel safety

SYMBOL LEVEL SEVERITY NO DOCUMENTS IMPACTED BY THIS FMEA(Applicable documents mark as √)

CRITICAL 9 & 10 CONTROL PLAN CTQ

NOTE:-SPECIAL CHARACTERISTICS IDENTIFICATION x SEVERE 6, 7 & 8 BOM OQC Checklist
NO SYMBOL LOW 1 T0 5 SPECIFIC WI PFC

Δ SAFETY 9 & 10 CONTROL PLAN CTQ

Rev. No. DESCRIPTION OF REVISIONS CARRIED OUT DATE Prepared Approved

Prepared By: (Executive - NPD) Reviewed By: (Executive - QA) Reviewed By: (Supervisor/HOD-Prod.) Reviewed By: (Project Manager) Approved By: (Moderator)

Sign: Sign: Sign: Sign: Sign:

Name: Ravi Ranjan Name: Ms Anitha M Name: Mr. Praveen Gautam Name: Mr . Sunil Name: Mr. Anmol Maheshwari

Date: 14.08.2020 Date: 14.08.2020 Date: 14.08.2020 Date: 14.08.2020 Date: 14.08.2020

Note1: The intent of any recommended action is to reduce ranking of Severity ,Occurrence and Detection
Note 2: See annexure for specific requirements ( customer / card)
Note 3: Potential failure mode to be identified based onTGR/TGW, product recalls, product audits, field returns and repairs, customer complaints, scrap and rework.
Note 4:Manufacturing process design and development output shall focus on error prevention rather than detection by using poka-yoke methods.

Page 12 of 39
 Form / Format FF NPD 15 Page No.: 1 of 2
Process FMEA ISSUE NO. 8 REV No: 4

PROCESS FMEA

Process Owner Mr. Sunil

FMEA No. KT7/SPFMEA/180 Core team: 1. Mr. Ajay Tyagi
REV No: 0 2. Ms. Divya Shree Date(Orignal): 14.08.2020
Project Name: IJL(YTA) 3. Mr. Praveen Gautam
Product Name: YTA CLL A & B PCBA 4. Mr. Sunil
Part No : 21009-8F051 5. Ms. Anitha
Revision No.: b 6. Mr. Arif
Date: 29.06.2020 7. Mr .Kartik Date(Revised): 14.08.2020
Drawing No: A8939 8. Mr. Anmol Maheshwari
KAYNES REPORT NO: Not Applicable 9. Mr.Pawan
10. Mr. Sonu Yadav FMEA prepared by: Ravi Ranjan
11. Mr. Govind Saini
12. Mr. Om Prakash
Responsi

Occurrence

Detection
bility & Action Results

Severity

RPN No
Potential Potential Recommended

Class
Process Name or Potential failure Current Process Current Process Target Action
Requirements Effect(s) of Cause(s)/Mecha Actions
Completi
Function Mode controls Prevention controls Detection s

RPN
Occ
Sev

Det
failure nism Failure(s) (Refer note 1)
on Date Taken

210.1 selection of Component Part no.

wrong selection Part no. not
Component Part PCB Damage 7 mentioned in 2 Job set up verification 5 70

x
of part mentioned
no. PFC/SPWI

Component
Wrong Refer work
210.2 Component description not
description PCB Damage 7 instruction 2 Job set up verification 5 70

x
Description mentioned in
mentioned KT7/SPWI/1049
PFC/SPWI

Refer work
210.3 Fixture ID wrong selection PCB Damage Not mentioned
7 instruction 2 Job set up verification 5 70
x

No. & Rev No of fixture Fitment Issue in PFC/SPWI

KT7/SPWI/1049

Refer work
210.4 Tool ID No. Wrong selection PCB Damage Not mentioned
7 instruction 2 Job set up verification 5 70
x

& Rev no of Tool Half screwing in PFC/SPWI

KT7/SPWI/1049

Damage of
Refer work
210.5 Required Wrong Torque PCB Not mentioned
7 instruction 2 Job set up verification 5 70
x

Torque Setting & Bracket in PFC/SPWI

KT7/SPWI/1049
Half Screwing

Wrong torque Damage of

Refer work
210.6 Measured measured and it PCB Not mentioned
7 instruction 2 Job set up verification 5 70
x

Torque is not in range & Bracket in PFC/SPWI

KT7/SPWI/1049
of 0.6 to 1Nm Half Screwing
210. Hardware fixing

Page 13 of 39
 Responsi

Occurrence

Detection
bility & Action Results

Severity

RPN No
Potential Potential Recommended

Class
Process Name or Potential failure Current Process Current Process Target Action
Requirements Effect(s) of Cause(s)/Mecha Actions
Completi
Function Mode controls Prevention controls Detection s

RPN
Occ
Sev

Det
failure nism Failure(s) (Refer note 1)
on Date Taken
210. Hardware fixing

Refer work
Fitment issue instruction
210.7 Update Missing of Not mentioned
Customer 7 KT7/SPWI/1049 2 Job set up verification 5 70

x
screw count no. screw in PFC/SPWI
Complaint PLC controlled
Hardware Jig

Bracket Assembly :
210.8 No Missing
of screws Trained Operator
210.9 No Damage Poka yoka jigs and
1. Missing of
to the Bracket tool available for Multiskilling Chart
Screws
210.10 No Half Un-Trained hardware fixing Poka yoka monitoring
2. Damage of
screwing 1. Fitment Operator Put tick mark with sheet
Bracket
210.11 No issue will come Jigs not white pencil on both Job set up verification
3.Half Screwing
Bracket warpage in Product 7 available Bracket A & B 2 OQC Report 5 70

x
4. Warpage in
210.12 No Loose 2. Customer No checklist or checkpoints mention PLC Controlled Jig
Bracket
Flash Complaint SPWI available in OQC checklist implemented, so jig
5. Loose Flash
210.13 No Rib for inspection specific WI will not open without
6. Damage rib
Damage KT7/SPWI/1049 completing of process
7. Short mould
210.14 No Short available for
Mould Hardware fixing
210.15 No Missing
of Bracket

Note: The following Dimensions considered while identifying potential effect of failures:
a. Effect on Customer
b. Effect on KT
c. Statutory and Regulatory
d. Product safety
e. Personnel safety

SYMBOL LEVEL SEVERITY NO DOCUMENTS IMPACTED BY THIS FMEA(Applicable documents mark as √)

CRITICAL 9 & 10 CONTROL PLAN CTQ

NOTE:-SPECIAL CHARACTERISTICS IDENTIFICATION x SEVERE 6, 7 & 8 BOM OQC Checklist
NO SYMBOL LOW 1 T0 5 SPECIFIC WI PFC

Δ SAFETY 9 & 10 CONTROL PLAN CTQ

Rev. No. DESCRIPTION OF REVISIONS CARRIED OUT DATE Prepared Approved

0 Initial Release 14.08.2020 Ravi Anmol Maheshwari

Prepared By: (Executive - NPD) Reviewed By: (Executive - QA) Reviewed By: (Supervisor/HOD-Prod.) Reviewed By: (Project Manager) Approved By: (Moderator)

Sign: Sign: Sign: Sign: Sign:

Name: Ravi Ranjan Name: Ms Anitha M Name: Mr. Praveen Gautam Name: Mr . Sunil Name: Mr. Anmol Maheshwari

Page 14 of 39
 Responsi

Occurrence

Detection
bility & Action Results

Severity

RPN No
Potential Potential Recommended

Class
Process Name or Potential failure Current Process Current Process Target Action
Requirements Effect(s) of Cause(s)/Mecha Actions
Completi
Function Mode controls Prevention controls Detection s

RPN
Occ
Sev

Det
failure nism Failure(s) (Refer note 1)
on Date Taken

Date: 14.08.2020 Date: 14.08.2020 Date: 14.08.2020 Date: 14.08.2020 Date: 14.08.2020

Note1: The intent of any recommended action is to reduce ranking of Severity ,Occurrence and Detection

Note 2: See annexure for specific requirements ( customer / card)

Note 3: Potential failure mode to be identified based onTGR/TGW, product recalls, product audits, field returns and repairs, customer complaints, scrap and rework.

Note 4:Manufacturing process design and development output shall focus on error prevention rather than detection by using poka-yoke methods.

Page 15 of 39
 Form / Format FF NPM 21 Page No.: 1 of 2
Process FMEA ISSUE NO. 9 REV No: 02

PROCESS FMEA
Process Owner : Mr.Jay Kishan
FMEA No. KT7/FMEA/620
REV No: 01
Project Name:PROJ-Neolite -KT-09
Product Name: Wire Harness Assy (N 1510)
Part No : 120000007240
CFT Members: Mr. Ravinder Dhankar, Mr. Abdul Kareem, Mr. Sunil
Revision No.: Rev-4 Date(Revised): 03.05.2025
Bhardwaj, Mr. Harishankar Tripathi, Mr. Kannan, Ms Kirtee,Mr Alok,Mr
Date: 03.05.2025 Jay kishan ,Mr Prakash ,Mr Abhishek ,Mr Lalit kumar .
Drawing No: HL-1510-034
KAYNES REPORT NO: Not Applicable
FMEA prepared by: Mr.Abhishek

Responsi

Occurrence

Detection
bility & Action Results

Severity

RPN No
Potential Potential Recommended

Class
Process Name or Potential failure Current Process Current Process Target Actions
Requirements Effect(s) of Cause(s)/Mecha Actions
Completi Taken
Function Mode controls Prevention controls Detection

RPN
Occ
Sev

Det
failure nism Failure(s) (Refer note 1)
on Date

Mix up of Cable's in
the same tray 100%
(Waiting for Visual 1. Visual Inspection Check
Inspection of
Inspection ) list 2 Separate red bin to be 7 84 Cable at IFM
Magnifier not used used for Rejected part.
30.1. Wire colour should be as per cutting chart.
1.Dimensionally not meet for inspection 2. Refer Specific work Stage
30.2. Wire specification should be as per cutting Backout Will Be Detected
specification instruction KT19/WI/001
chart by Tester with rejection
2.Strands missing Not meets the chute linkage provided
30.3. No Damage, Bend in Wire Insulation. 3. Inspection under 8X
3.Insulation damage specification , x
30.4. wire length as per drawing As per Cutting 6 magnifier
4.Nick mark/ Strands cut Customer Input, Output &
chart
30.5. No.of Strands in Wire as per cutting chart
Strip Length less/oversize Dissatisfaction Rejection Area not 2 7 84
5.cable length less / identified
30.6. Wire Stripping Length As per Cutting chart
oversize

100%
Checkpoints not Inspection of
defined
Refer checklist 2 Visual Inspection report 7 84 cable at IFM
Stage

30.Automatic wire cutting and

crimping machine

1.Un-Traind
Operator
2.No proper space 1.Specific work instruction
1.Operator Self
1 Crimp bend is Identified Displayed Master sample
Check
2. Crimp Height less 3. Guidelines not displayed
1. Multiskilling Chart 2.First 5 pieces
3. Wire Backout available for NC Trained operator used .
2. Line Side review inspection and
4. Damages are found 1. Product Failure product handling 2.Separate bins used for
3. Rework Report recorded in job
30.7 Crimping Height As per Cutting chart 5.Crimp Height more 2. Cable rejected 6 ● 4. Inspection with taping & with out 1
4. Scrap note
7 72 set up
30.8 Vinyl Height As per Cutting chart 6. correct specified part at customer end Traceability not taping parts storage
5. Visual Inspection Report verification
30.9 Crimping strength As per Cutting chart 7. No wire interchange mentioned Master sample displayed
6. IFM Report 3.100%
8. No Terminal bend 5. Same Bin is using 3. Refer Specific work
inspection done
9. Applicator failure mode for passed or instruction KT19/WI/001
in line
rejected Cable
6. Check points not
Defined in Checklist

Page 16 of 39
 Responsi

Occurrence

Detection
bility & Action Results

Severity

RPN No
Potential Potential Recommended

Class
Process Name or Potential failure Current Process Current Process Target Actions
Requirements Effect(s) of Cause(s)/Mecha Actions
Completi Taken
Function Mode controls Prevention controls Detection

RPN
Occ
Sev

Det
failure nism Failure(s) (Refer note 1)
on Date

Note: The following Dimensions considered while identifying potential effect of failures:
a. Effect on Customer
b. Effect on KT
c. Statutory and Regulatory
d. Product safety
e. Personnel safety
SYMBOL LEVEL SEVERITY NO DOCUMENTS IMPACTED BY THIS FMEA(Applicable documents mark as √)

CRITICAL 9 & 10 CONTROL PLAN CTQ

NOTE:-SPECIAL CHARACTERISTICS IDENTIFICATION x SEVERE 6, 7 & 8 BOM Visual Inspection Checklist
NO SYMBOL LOW 1 T0 5 SPECIFIC WI PFC

Δ SAFETY 9 & 10 CONTROL PLAN CTQ

Rev. No. DESCRIPTION OF REVISIONS CARRIED OUT DATE Prepared Approved

0 Initial Release 12.10.2022 Prakash Lalit Kumar
1 Revised for Updated Drawing 03.05.2025 Abhishek Lalit Kumar

Approved By: (NPD Head)

Prepared By: ( Executive - NPD) Reviewed By: (AM - QA) Reviewed By: (Supervisor/HOD-Prod.)
Sign:
Sign: Sign: Sign: Name: Mr Lalit Kumar
Name: Mr. ABHISHEK Name: Mr. ALOK Name: Mr.Jay Kishan Date: 03.05.2025
Date: 03.05.2025 Date: 03.05.2025 Date: 03.05.2025

Page 17 of 39
 Form / Format FF NPM 21 Page No.: 1 of 2
Process FMEA ISSUE NO. 9 REV No: 02
PROCESS FMEA
Process Owner : Mr.Jay Kishan
FMEA No. KT7/FMEA/620
REV No: 01
Project Name:PROJ-Neolite -KT-09

Product Name: Wire Harness Assy (N 1510)

Part No : 120000007240 CFT Members: Mr. Ravinder Dhankar, Mr. Abdul Kareem, Mr. Sunil
Revision No.: Rev-4 Bhardwaj, Mr. Harishankar Tripathi, Mr. Kannan, Ms Kirtee,Mr Alok,Mr Date(Revised): 03.05.2025
Date: 03.05.2025 Jay kishan ,Mr Prakash ,Mr Abhishek ,Mr Lalit kumar .
Drawing No: HL-1510-034
KAYNES REPORT NO: Not Applicable
FMEA prepared by: Mr. Abhishek

Responsibilit

Occurrence

Detection
y & Target Action Results

Severity

RPN No
Potential Potential Recommended

Class
Process Name or Current Process Current Process Completion Actions
Requirements Potential failure Mode Effect(s) of Cause(s)/Mecha Actions
Date
Function controls Prevention controls Detection Taken

RPN
Occ
Sev

Det
failure nism Failure(s) (Refer note 1)

Rejection at
customer end
No damage Customer 6 x 3 4 72
dissatisfaction

Rejection at
customer end 1.Separate red bin to be
Sleeve color Should be Black
Customer
6 x
used for Rejected part.
3 4 72
dissatisfaction Backout Will Be Detected
40.1 No Damages of 1. Mixing of the Self Check by Production
by Tester with rejection
Sleeve. empty trays and Operator
chute linkage provided
40.2 Sleeve Cut as per bins Dock Audit report
Rejection at 2. Refer KT7/SPWI/3201
cutting chart. 2.Mix up of Ok & 100% quality inspection to
customer end for Specific work
Not Ok part be done.
Cutting Properly No treaceability 6 x instruction Displayed 3 4 72
40.HST SLEEVE Customer Master sample displayed
CUTTING 40.3 correct sleeve dissatisfaction Trained operator used
should be place .
40.4 sleeve
specification must be Wrong shipment /
according to the Inconvenience to
drawing. Proper check the condition customer 6 x 3 4 72
Customer
dissatisfaction

Trained Operatoron
specific work 1.Multiskilling Chart
6 3 4 48
x

instruction 2. Dock Audit

KT7/SPWI/3201

Note: The following Dimensions considered while identifying potential effect of failures:
a. Effect on Customer
b. Effect on KT
c. Statutory and Regulatory
d. Product safety
e. Personnel safety

Page 18 of 39
 Responsibilit

Occurrence

Detection
y & Target Action Results

Severity

RPN No
Potential Potential Recommended

Class
Process Name or Current Process Current Process Completion Actions
Requirements Potential failure Mode Effect(s) of Cause(s)/Mecha Actions
Date
Function controls Prevention controls Detection Taken

RPN
Occ
Sev

Det
failure nism Failure(s) (Refer note 1)

SYMBOL LEVEL SEVERITY NO DOCUMENTS IMPACTED BY THIS FMEA(Applicable documents mark as √)

CRITICAL 9 & 10 CONTROL PLAN CTQ

NOTE:-SPECIAL CHARACTERISTICS IDENTIFICATION x SEVERE 6, 7 & 8 BOM OQC Checklist
NO SYMBOL LOW 1 T0 5 SPECIFIC WI PFC

Δ SAFETY 9 & 10 CONTROL PLAN CTQ

Rev. No. DESCRIPTION OF REVISIONS CARRIED OUT DATE Prepared Approved

0 Initial Release 12.10.2022 Prakash Lalit Kumar
1 Revised for Updated Drawing 03.05.2025 Abhishek Lalit Kumar

Approved By: (NPD Head)

Prepared By: ( Executive - NPD) Reviewed By: (AM - QA) Reviewed By: (Supervisor/HOD-Prod.)
Sign:
Sign: Sign: Sign: Name: Mr Lalit Kumar
Name: Mr. ABHISHEK Name: Mr. ALOK Name: Mr.Jay Kishan Date: 03.05.2025
Date: 03.05.2025 Date: 03.05.2025 Date: 03.05.2025

Page 19 of 39
 Form / Format FF NPM 21 Page No.: 1 of 2
Process FMEA ISSUE NO. 9 REV No: 02
PROCESS FMEA
Process Owner : Mr.Jay Kishan
FMEA No. KT7/FMEA/620
REV No: 01
Project Name:PROJ-Neolite -KT-09

Product Name: Wire Harness Assy (N 1510)

Part No : 120000007240 CFT Members: Mr. Ravinder Dhankar, Mr. Abdul Kareem, Mr. Sunil
Revision No.: Rev-4 Bhardwaj, Mr. Harishankar Tripathi, Mr. Kannan, Ms Kirtee,Mr Alok,Mr Date(Revised): 03.05.2025
Date: 03.05.2025 Jay kishan ,Mr Prakash ,Mr Abhishek ,Mr Lalit kumar .
Drawing No: HL-1510-034
KAYNES REPORT NO: Not Applicable
FMEA prepared by: Mr. Abhishek

Responsibilit

Occurrence

Detection
y & Target Action Results

Severity

RPN No
Potential Potential Recommended

Class
Process Name or Current Process Current Process Completion Actions
Requirements Potential failure Mode Effect(s) of Cause(s)/Mecha Actions
Date
Function controls Prevention controls Detection Taken

RPN
Occ
Sev

Det
failure nism Failure(s) (Refer note 1)

Rejection at
customer end
Strands Cuts Customer 6 x 3 4 72
dissatisfaction

Rejection at
customer end 1.Separate red bin to be
Crimp bend
Customer
6 x
used for Rejected part.
3 4 72
dissatisfaction Backout Will Be Detected
50.1 No damage in 1. Mixing of the Self Check by Production
by Tester with rejection
Joint Crimping. empty trays and Operator
chute linkage provided
50.2 No missing of bins Dock Audit report
Rejection at 2. Refer KT7/SPWI/3200
Joint Crimping. 2.Mix up of Ok & 100% quality inspection to
customer end for Specific work
Not Ok part be done.
Joint Properly No treaceability 6 x instruction Displayed 3 4 72
50.3 correct Joint Customer Master sample displayed
50.JOINT CRIMPING Crimping should be dissatisfaction Trained operator used
place .
50.4 Joint Crimping
specification must be Wrong shipment /
according to the Inconvenience to
drawing. Proper check the condition customer 6 x 3 4 72
Customer
dissatisfaction

Trained Operatoron
specific work 1.Multiskilling Chart
6 3 4 48
x

instruction 2. Dock Audit

KT7/SPWI/3200

Note: The following Dimensions considered while identifying potential effect of failures:
a. Effect on Customer
b. Effect on KT
c. Statutory and Regulatory
d. Product safety
e. Personnel safety

Page 20 of 39
 Responsibilit

Occurrence

Detection
y & Target Action Results

Severity

RPN No
Potential Potential Recommended

Class
Process Name or Current Process Current Process Completion Actions
Requirements Potential failure Mode Effect(s) of Cause(s)/Mecha Actions
Date
Function controls Prevention controls Detection Taken

RPN
Occ
Sev

Det
failure nism Failure(s) (Refer note 1)

SYMBOL LEVEL SEVERITY NO DOCUMENTS IMPACTED BY THIS FMEA(Applicable documents mark as √)

CRITICAL 9 & 10 CONTROL PLAN CTQ

NOTE:-SPECIAL CHARACTERISTICS IDENTIFICATION x SEVERE 6, 7 & 8 BOM OQC Checklist
NO SYMBOL LOW 1 T0 5 SPECIFIC WI PFC

Δ SAFETY 9 & 10 CONTROL PLAN CTQ

Rev. No. DESCRIPTION OF REVISIONS CARRIED OUT DATE Prepared Approved

0 Initial Release 12.10.2022 Prakash Lalit Kumar
1 Revised for Updated Drawing 03.05.2025 Abhishek Lalit Kumar

Approved By: (NPD Head)

Prepared By: ( Executive - NPD) Reviewed By: (AM - QA) Reviewed By: (Supervisor/HOD-Prod.)
Sign:
Sign: Sign: Sign: Name: Mr Lalit Kumar
Name: Mr. ABHISHEK Name: Mr. ALOK Name: Mr.Jay Kishan Date: 03.05.2025
Date: 03.05.2025 Date: 03.05.2025 Date: 03.05.2025

Page 21 of 39
 Form / Format FF NPM 21 Page No.: 1 of 2
Process FMEA ISSUE NO. 9 REV No: 02

PROCESS FMEA
Process Owner : Mr.Jay Kishan
FMEA No. KT7/FMEA/620
REV No: 01
Project Name:PROJ-Neolite -KT-09
Product Name: Wire Harness Assy (N 1510)
Part No : 120000007240
CFT Members: Mr. Ravinder Dhankar, Mr. Abdul Kareem, Mr. Sunil
Revision No.: Rev-4 Date(Revised): 03.05.2025
Bhardwaj, Mr. Harishankar Tripathi, Mr. Kannan, Ms Kirtee,Mr Alok,Mr
Date: 03.05.2025 Jay kishan ,Mr Prakash ,Mr Abhishek ,Mr Lalit kumar .
Drawing No: HL-1510-034
KAYNES REPORT NO: Not Applicable
FMEA prepared by: Mr.Abhishek

Responsi

Occurrence

Detection
bility & Action Results

Severity

RPN No
Potential Potential Recommended

Class
Process Name or Potential failure Current Process Current Process Target Actions
Requirements Effect(s) of Cause(s)/Mecha Actions
Completi Taken
Function Mode controls Prevention controls Detection

RPN
Occ
Sev

Det
failure nism Failure(s) (Refer note 1)
on Date

Mix up of Cable's in
the same tray 100%
(Waiting for Visual 1. Visual Inspection Check
Inspection of
Inspection ) list 2 Separate red bin to be 7 84 Cable at IFM
Magnifier not used used for Rejected part.
for inspection Stage
2. Refer Specific work Backout Will Be Detected
60.1 High Insulation . instruction KT7/SPWI/3202 by Tester with rejection
Not meets the 3. Inspection under 8X chute linkage provided
60.2 Low Insulation.
Dimensionally not meet specification , x magnifier
60.3 Side defect. 6
specification Customer Input, Output &
60.4 Pull force load 8.5KGF.
60.5 Terminal Part Number as per cutting chart
Dissatisfaction Rejection Area not 2 7 84
identified

100%
Checkpoints not Inspection of
defined
Refer checklist 2 Visual Inspection report 7 84 cable at IFM
Stage

60. MANUAL CRIMPING

1.Un-Traind
Operator
2.No proper space
1.Specific work instruction 1.Operator Self
is Identified
1 Crimp bend Displayed Master sample Check
3. Guidelines not
2. Crimp Height less displayed 1. Multiskilling Chart 2.First 5 pieces
available for NC
3. Wire Backout 1. Product Failure Trained operator used . 2. Line Side review inspection and
60.6 crimping Height As per Cutting chart product handling
4. Damages are found 2. Cable rejected 2.Separate bins used for 3. Rework Report recorded in job
60.7 Vinyl Height As per Cutting chart
5.Crimp Height more at customer end
6 ● 4. Inspection
with taping & with out
1
4. Scrap note
7 72 set up
60.8 Crimping strength As per Cutting chart Traceability not
6. correct specified part taping parts storage 5. Visual Inspection Report verification
mentioned
7. No wire interchange Master sample displayed 6. IFM Report 3.100%
5. Same Bin is using
8. No Terminal bend 3. Refer Specific work inspection done
for passed or
instruction KT7/SPWI/3202 in line
rejected Cable
6. Check points not
Defined in Checklist

Page 22 of 39
 Responsi

Occurrence

Detection
bility & Action Results

Severity

RPN No
Potential Potential Recommended

Class
Process Name or Potential failure Current Process Current Process Target Actions
Requirements Effect(s) of Cause(s)/Mecha Actions
Completi Taken
Function Mode controls Prevention controls Detection

RPN
Occ
Sev

Det
failure nism Failure(s) (Refer note 1)
on Date

Note: The following Dimensions considered while identifying potential effect of failures:
a. Effect on Customer
b. Effect on KT
c. Statutory and Regulatory
d. Product safety
e. Personnel safety
SYMBOL LEVEL SEVERITY NO DOCUMENTS IMPACTED BY THIS FMEA(Applicable documents mark as √)

CRITICAL 9 & 10 CONTROL PLAN CTQ

NOTE:-SPECIAL CHARACTERISTICS IDENTIFICATION x SEVERE 6, 7 & 8 BOM Visual Inspection Checklist
NO SYMBOL LOW 1 T0 5 SPECIFIC WI PFC

Δ SAFETY 9 & 10 CONTROL PLAN CTQ

Rev. No. DESCRIPTION OF REVISIONS CARRIED OUT DATE Prepared Approved

0 Initial Release 12.10.2022 Prakash Lalit Kumar
1 Revised for Updated Drawing 03.05.2025 Abhishek Lalit Kumar

Approved By: (NPD Head)

Prepared By: ( Executive - NPD) Reviewed By: (AM - QA) Reviewed By: (Supervisor/HOD-Prod.)
Sign:
Sign: Sign: Sign: Name: Mr Lalit Kumar
Name: Mr. ABHISHEK Name: Mr. ALOK Name: Mr.Jay Kishan Date: 03.05.2025
Date: 03.05.2025 Date: 03.05.2025 Date: 03.05.2025

Page 23 of 39
 Form / Format FF NPM 21 Page No.: 1 of 2
Process FMEA ISSUE NO. 9 REV No: 02
PROCESS FMEA
Process Owner : Mr.Jay Kishan
FMEA No. KT7/FMEA/620
REV No: 01
Project Name: PROJ-Neolite -KT-09

Product Name: Wire Harness Assy (N 1510)

Part No : 120000007240 CFT Members: Mr. Ravinder Dhankar, Mr. Abdul Kareem, Mr. Sunil
Revision No.: Rev-4 Bhardwaj, Mr. Harishankar Tripathi, Mr. Kannan, Ms Kirtee,Mr Alok,Mr Date(Revised): 03.05.2025
Jay kishan ,Mr Prakash ,Mr Abhishek ,Mr Lalit kumar .
Date: 03.05.2025
Drawing No: HL-1510-034
KAYNES REPORT NO: NA
FMEA prepared by: Mr. Abhishek

Responsibilit

Occurrence

Detection
y & Target Action Results

Severity

RPN No
Potential Potential Recommended Completion Actions

Class
Process Name or Potential failure Current Process Current Process
Requirements Effect(s) of Cause(s)/Mecha Actions
Date
Function Mode controls Prevention controls Detection Taken

RPN
Occ
Sev

Det
failure nism Failure(s) (Refer note 1)

Rejection at
customer end
Strands Cuts Customer 6 x 3 4 72
dissatisfaction

Rejection at
wire Insulation customer end 1.Separate red bin to be
70.1. No Wire Damage Customer
6 x
used for Rejected part.
3 4 72
Insulation Damage. dissatisfaction Backout Will Be Detected
70.2. No Wire Strands 1. Mixing of the Self Check by Production
by Tester with rejection
Loose. empty trays and Operator
chute linkage provided
70.3. No Low Core And bins Dock Audit report
Rejection at 2. Refer KT19/WI/002 for
No High Core. 2.Mix up of Ok & 100% quality inspection to
customer end Specific work instruction
70.4. No Less Improper diagonal Not Ok part be done.
No treaceability 6 x Displayed 3 4 72
70. CRIMPING Insulation And High of Terminal
Customer Master sample displayed
INSPECTION Insulation Crimp. dissatisfaction Trained operator used
70.5. No Terminal Burr.

Wrong shipment /
70.6. No Strands Cut. Inconvenience to
70.7. No Terminal Crimp bend/damage customer 6 x 3 4 72
Deformation Customer
dissatisfaction

Trained Operatoron
Less insulation/ specific work 1.Multiskilling Chart
6 3 4 48
x

Over insulation instruction 2. Dock Audit

KT19/WI/002

Note: The following Dimensions considered while identifying potential effect of failures:
a. Effect on Customer
b. Effect on KT
c. Statutory and Regulatory
d. Product safety
e. Personnel safety

Page 24 of 39
 Responsibilit

Occurrence

Detection
y & Target Action Results

Severity

RPN No
Potential Potential Recommended Completion Actions

Class
Process Name or Potential failure Current Process Current Process
Requirements Effect(s) of Cause(s)/Mecha Actions
Date
Function Mode controls Prevention controls Detection Taken

RPN
Occ
Sev

Det
failure nism Failure(s) (Refer note 1)

SYMBOL LEVEL SEVERITY NO DOCUMENTS IMPACTED BY THIS FMEA(Applicable documents mark as √)

CRITICAL 9 & 10 CONTROL PLAN CTQ

NOTE:-SPECIAL CHARACTERISTICS IDENTIFICATION x SEVERE 6, 7 & 8 BOM OQC Checklist
NO SYMBOL LOW 1 T0 5 SPECIFIC WI PFC
Δ SAFETY 9 & 10 CONTROL PLAN CTQ

Rev. No. DESCRIPTION OF REVISIONS CARRIED OUT DATE Prepared Approved

0 Initial Release 12.10.2022 Prakash Lalit Kumar
1 Revised for Updated Drawing 03.05.2025 Abhishek Lalit Kumar

Approved By: (NPD Head)

Prepared By: ( Executive - NPD) Reviewed By: (AM - QA) Reviewed By: (Supervisor/HOD-Prod.)
Sign:
Sign: Sign: Sign: Name: Mr Lalit Kumar
Name: Mr. ABHISHEK Name: Mr. ALOK Name: Mr.Jay Kishan Date: 03.05.2025
Date: 03.05.2025 Date: 03.05.2025 Date: 03.05.2025

Page 25 of 39
 Form / Format FF NPM 21 Page No.: 1 of 2
Process FMEA ISSUE NO. 9 REV No: 02
PROCESS FMEA
Process Owner : Mr.Jay Kishan
FMEA No. KT7/FMEA/620
REV No: 01
Project Name: PROJ-Neolite -KT-09

Product Name: Wire Harness Assy (N 1510)

Part No : 120000007240 CFT Members: Mr. Ravinder Dhankar, Mr. Abdul Kareem, Mr. Sunil
Revision No.: Rev-4 Bhardwaj, Mr. Harishankar Tripathi, Mr. Kannan, Ms Kirtee,Mr Alok,Mr Date(Revised): 03.05.2025
Date: 03.05.2025 Jay kishan ,Mr Prakash ,Mr Abhishek ,Mr Lalit kumar .
Drawing No: HL-1510-034
KAYNES REPORT NO: NA
FMEA prepared by: Mr. Abhishek

Responsibilit

Occurrence

Detection
y & Target Action Results

Severity

RPN No
Potential Potential Recommended Completion Actions

Class
Process Name or Potential failure Current Process Current Process
Requirements Effect(s) of Cause(s)/Mecha Actions
Date
Function Mode controls Prevention controls Detection Taken

RPN
Occ
Sev

Det
failure nism Failure(s) (Refer note 1)

Rejection at
customer end
Grommet Cuts Customer 6 x 3 4 72
dissatisfaction
80.1 No damage of
Grommet.
80.2 No missing of
Rejection at
Grommet.
customer end 1.Separate red bin to be
80.3 Grommet outer body outer body okay
Customer
6 x
used for Rejected part.
3 4 72
should be okay.
dissatisfaction Backout Will Be Detected
80.4 No damage of wire 1. Mixing of the Self Check by Production
by Tester with rejection
seal. empty trays and Operator
chute linkage provided
80.5 No misssing of wire bins Dock Audit report
Rejection at 2. Refer KT7/SPWI/3203
seal . 2.Mix up of Ok & 100% quality inspection to
customer end for Specific work
80.6 No damage of HST Not Ok part be done.
seelve .
Insertion Properly No treaceability 6 x instruction Displayed 3 4 72
Customer Master sample displayed
80.7 No missing of HST
dissatisfaction Trained operator used
80. PART FITTING seelve .

80.8 Correct Grommet

Wrong shipment /
should be used .
Inconvenience to
80.9 Correct Grommet Proper check the
specification should be as condition
customer 6 x 3 4 72
Customer
per drawing.
dissatisfaction
80.10 correct wire seal
should be used(Green
Holder).
80.11 Wire seal insert
according to the drawing. Trained Operatoron
80.12 correct seelve
should be used. specific work 1.Multiskilling Chart
6 3 4 48
x

instruction 2. Dock Audit

KT7/SPWI/3203

Note: The following Dimensions considered while identifying potential effect of failures:
a. Effect on Customer
b. Effect on KT
c. Statutory and Regulatory
d. Product safety
e. Personnel safety

Page 26 of 39
 Responsibilit

Occurrence

Detection
y & Target Action Results

Severity

RPN No
Potential Potential Recommended Completion Actions

Class
Process Name or Potential failure Current Process Current Process
Requirements Effect(s) of Cause(s)/Mecha Actions
Date
Function Mode controls Prevention controls Detection Taken

RPN
Occ
Sev

Det
failure nism Failure(s) (Refer note 1)

SYMBOL LEVEL SEVERITY NO DOCUMENTS IMPACTED BY THIS FMEA(Applicable documents mark as √)

CRITICAL 9 & 10 CONTROL PLAN CTQ

NOTE:-SPECIAL CHARACTERISTICS IDENTIFICATION x SEVERE 6, 7 & 8 BOM OQC Checklist
NO SYMBOL LOW 1 T0 5 SPECIFIC WI PFC
Δ SAFETY 9 & 10 CONTROL PLAN CTQ

Rev. No. DESCRIPTION OF REVISIONS CARRIED OUT DATE Prepared Approved

0 Initial Release 12.10.2022 Prakash Lalit Kumar
1 Revised for Updated Drawing 03.05.2025 Abhishek Lalit Kumar

Approved By: (NPD Head)

Prepared By: ( Executive - NPD) Reviewed By: (AM - QA) Reviewed By: (Supervisor/HOD-Prod.)
Sign:
Sign: Sign: Sign: Name: Mr Lalit Kumar
Name: Mr. ABHISHEK Name: Mr. ALOK Name: Mr.Jay Kishan Date: 03.05.2025
Date: 03.05.2025 Date: 03.05.2025 Date: 03.05.2025

Page 27 of 39
 Form / Format FF NPM 21 Page No.: 1 of 2
Process FMEA ISSUE NO. 9 REV No: 02

PROCESS FMEA
Process Owner : Mr.Jay Kishan
FMEA No. KT7/FMEA/620
REV No: 01
Project Name:PROJ-Neolite -KT-09
Product Name: Wire Harness Assy (N 1510)
Part No : 120000007240
CFT Members: Mr. Ravinder Dhankar, Mr. Abdul Kareem, Mr. Sunil
Revision No.: Rev-4 Date(Revised): 03.05.2025
Bhardwaj, Mr. Harishankar Tripathi, Mr. Kannan, Ms Kirtee,Mr Alok,Mr
Date: 03.05.2025 Jay kishan ,Mr Prakash ,Mr Abhishek ,Mr Lalit kumar .
Drawing No: HL-1510-034
KAYNES REPORT NO: Not Applicable
FMEA prepared by: Mr.Abhishek

Responsi

Occurrence

Detection
bility & Action Results

Severity

RPN No
Potential Potential Recommended

Class
Process Name or Potential failure Current Process Current Process Target Actions
Requirements Effect(s) of Cause(s)/Mecha Actions
Completi Taken
Function Mode controls Prevention controls Detection

RPN
Occ
Sev

Det
failure nism Failure(s) (Refer note 1)
on Date

Mix up of Cable's in
the same tray 100%
(Waiting for Visual 1. Visual Inspection Check
Inspection of
Inspection ) list 2 Separate red bin to be 7 84 Cable at IFM
Magnifier not used used for Rejected part.
for inspection Stage
2. Refer Specific work Backout Will Be Detected
90.1. No damage of connector instruction KT7/SPWI/3204 by Tester with rejection
90.2. No wire damage Not meets the 3. Inspection under 8X chute linkage provided
90.3. No Terminal bend Wire length should be less specification , x magnifier
6
90.4. No wire Interchange or over Customer Input, Output &
90.5 Connector Part Number As per sub assy Dissatisfaction Rejection Area not 2 7 84
Diagram identified

100%
Checkpoints not Inspection of
defined
Refer checklist 2 Visual Inspection report 7 84 cable at IFM
Stage

90. SUB ASSEMBLY

1.Un-Traind
Operator
1.Specific work instruction
2.No proper space
1. Missing of wires Displayed 1.Operator Self
is Identified
insertion in to connector connector aseembly Check
3. Guidelines not
2. Wires not locked firmly template provided 1. Multiskilling Chart 2.First 5 pieces
available for NC
into housing 1. Product Failure Master sample displayed 2. Line Side review inspection and
90.6. Proper crimp check product handling
3. Wire Backout 2. Cable rejected Trained operator used . 3. Rework Report recorded in job
90.7. Proper crimp lock in connector
4. Damages are found at customer end
6 ● 4. Inspection
2.Separate bins used for
1
4. Scrap note
7 72 set up
90.8 Terminal Backout Traceability not
5.Connector Damages with taping & with out 5. Visual Inspection Report verification
mentioned
6. correct specified part taping parts storage 6. IFM Report 3.100%
5. Same Bin is using
7. No wire interchange Master sample displayed inspection done
for passed or
8. No Terminal bend 3. Refer Specific work in line
rejected Cable
instruction KT7/SPWI/3204
6. Check points not
Defined in Checklist

Page 28 of 39
 Responsi

Occurrence

Detection
bility & Action Results

Severity

RPN No
Potential Potential Recommended

Class
Process Name or Potential failure Current Process Current Process Target Actions
Requirements Effect(s) of Cause(s)/Mecha Actions
Completi Taken
Function Mode controls Prevention controls Detection

RPN
Occ
Sev

Det
failure nism Failure(s) (Refer note 1)
on Date

Note: The following Dimensions considered while identifying potential effect of failures:
a. Effect on Customer
b. Effect on KT
c. Statutory and Regulatory
d. Product safety
e. Personnel safety
SYMBOL LEVEL SEVERITY NO DOCUMENTS IMPACTED BY THIS FMEA(Applicable documents mark as √)

CRITICAL 9 & 10 CONTROL PLAN CTQ

NOTE:-SPECIAL CHARACTERISTICS IDENTIFICATION x SEVERE 6, 7 & 8 BOM Visual Inspection Checklist
NO SYMBOL LOW 1 T0 5 SPECIFIC WI PFC

Δ SAFETY 9 & 10 CONTROL PLAN CTQ

Rev. No. DESCRIPTION OF REVISIONS CARRIED OUT DATE Prepared Approved

0 Initial Release 12.10.2022 Prakash Lalit Kumar
1 Revised for Updated Drawing 03.05.2025 Abhishek Lalit Kumar

Approved By: (NPD Head)

Prepared By: ( Executive - NPD) Reviewed By: (AM - QA) Reviewed By: (Supervisor/HOD-Prod.)
Sign:
Sign: Sign: Sign: Name: Mr Lalit Kumar
Name: Mr. ABHISHEK Name: Mr. ALOK Name: Mr.Jay Kishan Date: 03.05.2025
Date: 03.05.2025 Date: 03.05.2025 Date: 03.05.2025

Page 29 of 39
 Form / Format FF NPM 21 Page No.: 1 of 2
Process FMEA ISSUE NO. 9 REV No: 02

PROCESS FMEA
Process Owner : Mr.Jay Kishan
FMEA No. KT7/FMEA/620
REV No: 01
Project Name:PROJ-Neolite -KT-09
Product Name: Wire Harness Assy (N 1510)
Part No : 120000007240
CFT Members: Mr. Ravinder Dhankar, Mr. Abdul Kareem, Mr. Sunil
Revision No.: Rev-4 Date(Revised): 03.05.2025
Bhardwaj, Mr. Harishankar Tripathi, Mr. Kannan, Ms Kirtee,Mr Alok,Mr
Date: 03.05.2025 Jay kishan ,Mr Prakash ,Mr Abhishek ,Mr Lalit kumar .
Drawing No: HL-1510-034
KAYNES REPORT NO: Not Applicable
FMEA prepared by: Mr.Abhishek

Responsi

Occurrence

Detection
bility & Action Results

Severity

RPN No
Potential Potential Recommended

Class
Process Name or Potential failure Current Process Current Process Target Actions
Requirements Effect(s) of Cause(s)/Mecha Actions
Completi Taken
Function Mode controls Prevention controls Detection

RPN
Occ
Sev

Det
failure nism Failure(s) (Refer note 1)
on Date

Mix up of Cable's in
the same tray 100%
(Waiting for Visual 1. Visual Inspection Check
Inspection of
Inspection ) list 2 Separate red bin to be 7 84 Cable at IFM
Magnifier not used used for Rejected part.
for inspection Stage
2. Refer Specific work Backout Will Be Detected
instruction KT7/SPWI/3205 by Tester with rejection
100.1. Wire Colour should be ok Not meets the 3. Inspection under 8X chute linkage provided
100.2. No loose Taping Improper position of specification , x magnifier
6
100.3. Correct position of Taping Taping Customer Input, Output &
Dissatisfaction Rejection Area not 2 7 84
identified

100%
Checkpoints not Inspection of
defined
Refer checklist 2 Visual Inspection report 7 84 cable at IFM
Stage

100. Taping

1.Un-Traind
Operator
1. Loose Taping 1.Specific work instruction
2.No proper space
2. Improper length of Displayed 1.Operator Self
is Identified
tapping Tape Wrapping template Check
100.4. Taping properly 3. Guidelines not
3. Tapping completion provided 1. Multiskilling Chart 2.First 5 pieces
100.5. Check the Cleanliness of the Jig/Bins/Trays. available for NC
mark not available on 1. Product Failure Master sample displayed 2. Line Side review inspection and
100.6. Physical Condition of the Jig. product handling
Cable 2. Cable rejected Trained operator used . 3. Rework Report recorded in job
100.7. Insert/Place the Cable into the Fixture and
4. Damages are found at customer end
6 ● 4. Inspection
2.Separate bins used for
1
4. Scrap note
7 72 set up
ensure that Connector is Sitting in the Fixture Firmly Traceability not
5.No tape missing during with taping & with out 5. Visual Inspection Report verification
and Freely. mentioned
assembly taping parts storage 6. IFM Report 3.100%
100.8. Taping length 490mm. 5. Same Bin is using
6. Improper color of tape Master sample displayed inspection done
for passed or
7. Tape Peel -off 3. Refer Specific work in line
rejected Cable
8. cable scratch instruction KT7/SPWI/3205
6. Check points not
Defined in Checklist

Page 30 of 39
 Responsi

Occurrence

Detection
bility & Action Results

Severity

RPN No
Potential Potential Recommended

Class
Process Name or Potential failure Current Process Current Process Target Actions
Requirements Effect(s) of Cause(s)/Mecha Actions
Completi Taken
Function Mode controls Prevention controls Detection

RPN
Occ
Sev

Det
failure nism Failure(s) (Refer note 1)
on Date

Note: The following Dimensions considered while identifying potential effect of failures:
a. Effect on Customer
b. Effect on KT
c. Statutory and Regulatory
d. Product safety
e. Personnel safety
SYMBOL LEVEL SEVERITY NO DOCUMENTS IMPACTED BY THIS FMEA(Applicable documents mark as √)

CRITICAL 9 & 10 CONTROL PLAN CTQ

NOTE:-SPECIAL CHARACTERISTICS IDENTIFICATION x SEVERE 6, 7 & 8 BOM Visual Inspection Checklist
NO SYMBOL LOW 1 T0 5 SPECIFIC WI PFC

Δ SAFETY 9 & 10 CONTROL PLAN CTQ

Rev. No. DESCRIPTION OF REVISIONS CARRIED OUT DATE Prepared Approved

0 Initial Release 12.10.2022 Prakash Lalit Kumar
1 Revised for Updated Drawing 03.05.2025 Abhishek Lalit Kumar

Approved By: (NPD Head)

Prepared By: ( Executive - NPD) Reviewed By: (AM - QA) Reviewed By: (Supervisor/HOD-Prod.)
Sign:
Sign: Sign: Sign: Name: Mr Lalit Kumar
Name: Mr. ABHISHEK Name: Mr. ALOK Name: Mr.Jay Kishan Date: 03.05.2025
Date: 03.05.2025 Date: 03.05.2025 Date: 03.05.2025

Page 31 of 39
 Form / Format FF NPM 21 Page No.: 1 of 2
Process FMEA ISSUE NO. 9 REV No: 02
PROCESS FMEA
Process Owner : Mr.Jay Kishan
FMEA No. KT7/FMEA/620
REV No: 01
Project Name:PROJ-Neolite -KT-09

Product Name: Wire Harness Assy (N 1510)

Part No : 120000007240 CFT Members: Mr. Ravinder Dhankar, Mr. Abdul Kareem, Mr. Sunil
Revision No.: Rev-4 Bhardwaj, Mr. Harishankar Tripathi, Mr. Kannan, Ms Kirtee,Mr Alok,Mr Date(Revised): 03.05.2025
Date: 03.05.2025 Jay kishan ,Mr Prakash ,Mr Abhishek ,Mr Lalit kumar .
Drawing No: HL-1510-034
KAYNES REPORT NO: Not Applicable
FMEA prepared by: Mr. Abhishek

Responsibilit

Occurrence

Detection
y & Target Action Results

Severity

RPN No
Potential Potential Recommended

Class
Process Name or Current Process Current Process Completion Actions
Requirements Potential failure Mode Effect(s) of Cause(s)/Mecha Actions
Date
Function controls Prevention controls Detection Taken

RPN
Occ
Sev

Det
failure nism Failure(s) (Refer note 1)

Rejection at
customer end
Strands Cuts Customer 6 x 3 4 72
dissatisfaction

Rejection at
customer end 1.Separate red bin to be
Crimp bend
Customer
6 x
used for Rejected part.
3 4 72
dissatisfaction Backout Will Be Detected
1. Mixing of the Self Check by Production
by Tester with rejection
110.1 No Damage & empty trays and Operator
chute linkage provided
Missing Clamp . bins Dock Audit report
Rejection at 2. Refer KT7/SPWI/3206
110.2 As par drawing 2.Mix up of Ok & 100% quality inspection to
customer end for Specific work
clamp should be ok Not Ok part be done.
Joint Properly No treaceability 6 x instruction Displayed 3 4 72
110.CLAMP 110.3 Position of Clamp Customer Master sample displayed
ATTACHMENT should be okay dissatisfaction Trained operator used
110.4 No Loose Clamp
110.5 No brack Clip Wrong shipment /
Allow Inconvenience to
Proper check the condition customer 6 x 3 4 72
Customer
dissatisfaction

Trained Operatoron
specific work 1.Multiskilling Chart
6 3 4 48
x

instruction 2. Dock Audit

KT7/SPWI/3206

Note: The following Dimensions considered while identifying potential effect of failures:
a. Effect on Customer
b. Effect on KT
c. Statutory and Regulatory
d. Product safety
e. Personnel safety

Page 32 of 39
 Responsibilit

Occurrence

Detection
y & Target Action Results

Severity

RPN No
Potential Potential Recommended

Class
Process Name or Current Process Current Process Completion Actions
Requirements Potential failure Mode Effect(s) of Cause(s)/Mecha Actions
Date
Function controls Prevention controls Detection Taken

RPN
Occ
Sev

Det
failure nism Failure(s) (Refer note 1)

SYMBOL LEVEL SEVERITY NO DOCUMENTS IMPACTED BY THIS FMEA(Applicable documents mark as √)

CRITICAL 9 & 10 CONTROL PLAN CTQ

NOTE:-SPECIAL CHARACTERISTICS IDENTIFICATION x SEVERE 6, 7 & 8 BOM OQC Checklist
NO SYMBOL LOW 1 T0 5 SPECIFIC WI PFC

Δ SAFETY 9 & 10 CONTROL PLAN CTQ

Rev. No. DESCRIPTION OF REVISIONS CARRIED OUT DATE Prepared Approved

0 Initial Release 12.10.2022 Prakash Lalit Kumar
1 Revised for Updated Drawing 03.05.2025 Abhishek Lalit Kumar

Approved By: (NPD Head)

Prepared By: ( Executive - NPD) Reviewed By: (AM - QA) Reviewed By: (Supervisor/HOD-Prod.)
Sign:
Sign: Sign: Sign: Name: Mr Lalit Kumar
Name: Mr. ABHISHEK Name: Mr. ALOK Name: Mr.Jay Kishan Date: 03.05.2025
Date: 03.05.2025 Date: 03.05.2025 Date: 03.05.2025

Page 33 of 39
 Form / Format FF NPM 21 Page No.: 1 of 2
Process FMEA ISSUE NO. 9 REV No: 02

PROCESS FMEA
Process Owner : Mr.Jay Kishan
FMEA No. KT7/FMEA/620
REV No: 01
Project Name:PROJ-Neolite -KT-09
Product Name: Wire Harness Assy (N 1510)
Part No : 120000007240
CFT Members: Mr. Ravinder Dhankar, Mr. Abdul Kareem, Mr. Sunil
Revision No.: Rev-4 Date(Revised): 03.05.2025
Bhardwaj, Mr. Harishankar Tripathi, Mr. Kannan, Ms Kirtee,Mr Alok,Mr
Date: 03.05.2025 Jay kishan ,Mr Prakash ,Mr Abhishek ,Mr Lalit kumar .
Drawing No: HL-1510-034
KAYNES REPORT NO: Not Applicable
FMEA prepared by: Mr.Abhishek

Responsi

Occurrence

Detection
bility & Action Results

Severity

RPN No
Potential Potential Recommended

Class
Process Name or Potential failure Current Process Current Process Target Actions
Requirements Effect(s) of Cause(s)/Mecha Actions
Completi Taken
Function Mode controls Prevention controls Detection

RPN
Occ
Sev

Det
failure nism Failure(s) (Refer note 1)
on Date

Mix up of Cable's in
the same tray
(Waiting for Visual 100%
Inspection and for 1. Visual Inspection Check Inspection of
Packing) list 2 Separate red bin to be 8 128 Cable at IFM
Magnifier not used used for Rejected part. Stage
120.1. Continuity Testing ok for inspection 2. Refer Specific work Backout Will Be Detected
120.2. No connector Damage instruction KT7/SPWI/3207 by Tester with rejection
120.3.Shown in Display PASS OR FAIL Functional failure 3. Inspection under 8X chute linkage provided
Connectivity not as per x magnifier
120.4. Auto Dot Punch mark in Main connector after Cutomer 8
requirement Input, Output &
ok dissatisfaction
Rejection Area not 2 6 96
identified

100%
Checkpoints not Refer Visual Inspection Inspection of
defined checklist
2 Visual Inspection report 8 128 cable at IFM
Stage

120. CIRCUIT TESTING

1. Trained Operator
2. working stage is
1.Un-Traind
identified with input and
1. Date code illigibitlity Operator
output wise
2. Bar code not available 2.No proper space
3. separate foam or bin
on Cable is Identified 1.Operator Self
available in production
3. Testing completion 3. Guidelines not Check
floor for handling of Cable
mark not available on available for NC 1. Multiskilling Chart 2.First 5 pieces
4. Rejected boards placed
120.5. NG wire fail shown in display Cable 1. Product Failure product handling 2. Line Side review inspection and
in rejection bin
120.6. Wire Short 4. Damages are found 2. Cable rejected 4. inspection 3. Rework Report recorded in job
120.7 Terminal Backout 5. Improper soldering of at customer end
9 ●
Traceability not
5. Put QC intial on QC 1
4. Scrap note
8 72 set up
Passed sticker
120.8 wire Interchange components and mentioned 5. Visual Inspection Report verification
6. WI QAM 10 For
connector 5. Same Bin is using 6. IFM Report 3.100%
Handling of NC Product
6. damage of components for passed or inspection done
7. FT system is
and cable rejected Cable in line
interlinked with each other
7. Excess Burr 6. Check points not
8. Visual Inspection
8. cable scratch Defined in Visual
Checklist
Inspection Checklist
9. Refer Specific work
instruction KT7/SPWI/3207

Page 34 of 39
 Responsi

Occurrence

Detection
bility & Action Results

Severity

RPN No
Potential Potential Recommended

Class
Process Name or Potential failure Current Process Current Process Target Actions
Requirements Effect(s) of Cause(s)/Mecha Actions
Completi Taken
Function Mode controls Prevention controls Detection

RPN
Occ
Sev

Det
failure nism Failure(s) (Refer note 1)
on Date

Note: The following Dimensions considered while identifying potential effect of failures:
a. Effect on Customer
b. Effect on KT
c. Statutory and Regulatory
d. Product safety
e. Personnel safety
SYMBOL LEVEL SEVERITY NO DOCUMENTS IMPACTED BY THIS FMEA(Applicable documents mark as √)

CRITICAL 9 & 10 CONTROL PLAN CTQ

NOTE:-SPECIAL CHARACTERISTICS IDENTIFICATION x SEVERE 6, 7 & 8 BOM Visual Inspection Checklist
NO SYMBOL LOW 1 T0 5 SPECIFIC WI PFC

Δ SAFETY 9 & 10 CONTROL PLAN CTQ

Rev. No. DESCRIPTION OF REVISIONS CARRIED OUT DATE Prepared Approved

0 Initial Release 12.10.2022 Prakash Lalit Kumar
1 Revised for Updated Drawing 03.05.2025 Abhishek Lalit Kumar

Approved By: (NPD Head)

Prepared By: ( Executive - NPD) Reviewed By: (AM - QA) Reviewed By: (Supervisor/HOD-Prod.)
Sign:
Sign: Sign: Sign: Name: Mr Lalit Kumar
Name: Mr. ABHISHEK Name: Mr. ALOK Name: Mr.Jay Kishan Date: 03.05.2025
Date: 03.05.2025 Date: 03.05.2025 Date: 03.05.2025

Page 35 of 39
 Form / Format FF NPM 21 Page No.: 1 of 2
Process FMEA ISSUE NO. 9 REV No: 02

PROCESS FMEA
Process Owner : Mr.Jay Kishan
FMEA No. KT7/FMEA/620
REV No: 01
Project Name:PROJ-Neolite -KT-09
Product Name: Wire Harness Assy (N 1510)
Part No : 120000007240
CFT Members: Mr. Ravinder Dhankar, Mr. Abdul Kareem, Mr. Sunil
Revision No.: Rev-4 Date(Revised): 03.05.2025
Bhardwaj, Mr. Harishankar Tripathi, Mr. Kannan, Ms Kirtee,Mr Alok,Mr
Date: 03.05.2025 Jay kishan ,Mr Prakash ,Mr Abhishek ,Mr Lalit kumar .
Drawing No: HL-1510-034
KAYNES REPORT NO: Not Applicable
FMEA prepared by: Mr.Abhishek

Responsi

Occurrence

Detection
bility & Action Results

Severity

RPN No
Potential Potential Recommended

Class
Process Name or Potential failure Current Process Current Process Target Actions
Requirements Effect(s) of Cause(s)/Mecha Actions
Completi Taken
Function Mode controls Prevention controls Detection

RPN
Occ
Sev

Det
failure nism Failure(s) (Refer note 1)
on Date

Mix up of Cable's in
the same tray
(Waiting for Visual 100%
Inspection and for 1. Visual Inspection Check Inspection of
Packing) list 2 8 128 Cable at IFM
Magnifier not used 1. Visual Inspection Report Stage
for inspection 2. Refer Specific work
2. Dock audit
instruction KT7/SPWI/3208
130.1 wire length check properly. 3. Inspection under 8X
130.2 No wire damage . Cable Assy should be Cable rejected at x magnifier
8
130.3 No wire interchange. defect free customer end Input, Output &
130.4 No damage of connector. Rejection Area not 2 6 96
identified

100%
Checkpoints not Refer Visual Inspection Inspection of
defined checklist
2 Visual Inspection report 8 128 cable at IFM
Stage

130. Visual Inspection

1. Trained Operator
2. working stage is
1.Un-Traind
1. Mix-up of Pass and identified with input and
Operator
Rejected boards output wise
2.No proper space
2. bar code not available 3. separate foam or bin
is Identified
on Cable available in production
3. Guidelines not
3. Testing completion floor for handling of Cable
130.5 No mix up of Visual Inspection pass and available for NC 1. Multiskilling Chart
mark not available on 4. Rejected boards placed
rejected Wire Harness 1. Product Failure product handling 2. Line Side review
Cable in rejection bin
130.6 Check for Testing completion mark 2. Cable rejected 4. inspection 3. Rework Report
130.7 Terminal Backout
4. led Damage
at customer end
9 ●
Traceability not
5. Put QC intial on QC 1
4. Scrap note
8 72
5. Improper soldering of Passed sticker
mentioned 5. Visual Inspection Report
components and 6. WI QAM 10 For
5. Same Bin is using 6. IFM Report
connector Handling of NC Product
for passed or
6. damage of components 7. FT system is
rejected Cable
and cable interlinked with each other
6. Check points not
7. Excess Burr 8. Visual Inspection
Defined in Visual
8. cable scratch Checklist
Inspection Checklist
9. Refer Specific work
instruction KT7/SPWI/3208

Page 36 of 39
 Responsi

Occurrence

Detection
bility & Action Results

Severity

RPN No
Potential Potential Recommended

Class
Process Name or Potential failure Current Process Current Process Target Actions
Requirements Effect(s) of Cause(s)/Mecha Actions
Completi Taken
Function Mode controls Prevention controls Detection

RPN
Occ
Sev

Det
failure nism Failure(s) (Refer note 1)
on Date

Note: The following Dimensions considered while identifying potential effect of failures:
a. Effect on Customer
b. Effect on KT
c. Statutory and Regulatory
d. Product safety
e. Personnel safety
SYMBOL LEVEL SEVERITY NO DOCUMENTS IMPACTED BY THIS FMEA(Applicable documents mark as √)

CRITICAL 9 & 10 CONTROL PLAN CTQ

NOTE:-SPECIAL CHARACTERISTICS IDENTIFICATION x SEVERE 6, 7 & 8 BOM Visual Inspection Checklist
NO SYMBOL LOW 1 T0 5 SPECIFIC WI PFC

Δ SAFETY 9 & 10 CONTROL PLAN CTQ

Rev. No. DESCRIPTION OF REVISIONS CARRIED OUT DATE Prepared Approved

0 Initial Release 12.10.2022 Prakash Lalit Kumar
1 Revised for Updated Drawing 03.05.2025 Abhishek Lalit Kumar

Approved By: (NPD Head)

Prepared By: ( Executive - NPD) Reviewed By: (AM - QA) Reviewed By: (Supervisor/HOD-Prod.)
Sign:
Sign: Sign: Sign: Name: Mr Lalit Kumar
Name: Mr. ABHISHEK Name: Mr. ALOK Name: Mr.Jay Kishan Date: 03.05.2025
Date: 03.05.2025 Date: 03.05.2025 Date: 03.05.2025

Page 37 of 39
 Form / Format FF NPM 21 Page No.: 1 of 2
Process FMEA ISSUE NO. 9 REV No: 02
PROCESS FMEA
Process Owner : Mr.Jay Kishan
FMEA No. KT7/FMEA/620
REV No: 01
Project Name: PROJ-Neolite -KT-09

Product Name: Wire Harness Assy (N 1510)

Part No : 120000007240 CFT Members: Mr. Ravinder Dhankar, Mr. Abdul Kareem, Mr. Sunil
Revision No.: Rev-4 Bhardwaj, Mr. Harishankar Tripathi, Mr. Kannan, Ms Kirtee,Mr Alok,Mr Date(Revised): 03.05.2025
Date: 03.05.2025 Jay kishan ,Mr Prakash ,Mr Abhishek ,Mr Lalit kumar .
Drawing No: HL-1510-034
KAYNES REPORT NO: NA
FMEA prepared by: Mr. Abhishek

Responsi

Occurrence

Detection
bility & Action Results

Severity

RPN No
Potential Potential Recommended

Class
Process Name or Potential failure Current Process Current Process Target Actions
Requirements Effect(s) of Cause(s)/Mecha Actions
Completi Taken
Function Mode controls Prevention controls Detection

RPN
Occ
Sev

Det
failure nism Failure(s) (Refer note 1)
on Date

Rejection at
customer end
No proper Packing Customer 6 x 2 6 72
dissatisfaction

Rejection at 1.Specific Packing

customer end Specification given
Damage parts
Customer
6 x
1. Mixing of the (Packing cup , poly cover ,
2 6 72
140.1. WIRE HARNESS dissatisfaction empty trays and carton box)
to be packed in bins 2. Refer KT7/SPWI/3209 Self Check by Production
specified Poly Bag 2. Mixing of the for packing Operator
Packed covers and 3. Packing Slip Dock Audit report
empty covers 4. Dock Audit
140.2. No missing of Wrong Parts Mixup 6 x In adequate 5. Mark on cable after 2 6 72
140. Packing WIRE HARNESS in operator training inspection
Poly Bag Rejected label pasted on
140.3. No Water/ NG parts
Moisture/Dust Inside
the Poly Bag Wrong shipment /
140.4. No damage of Inconvenience to
Wire Dimension mismatch customer 6 x 2 6 72
Customer
dissatisfaction

Trained Operatoron
Moisture or dust In adequate
specific work 1.Multiskilling Chart
inside the ESD Failure 6 operator 2 4 48
x

instruction 2. Dock Audit

Packing Box training
KT7/SPWI/3209

Note: The following Dimensions considered while identifying potential effect of failures:
a. Effect on Customer
b. Effect on KT
c. Statutory and Regulatory
d. Product safety
e. Personnel safety

Page 38 of 39
 Responsi

Occurrence

Detection
bility & Action Results

Severity

RPN No
Potential Potential Recommended

Class
Process Name or Potential failure Current Process Current Process Target Actions
Requirements Effect(s) of Cause(s)/Mecha Actions
Completi Taken
Function Mode controls Prevention controls Detection

RPN
Occ
Sev

Det
failure nism Failure(s) (Refer note 1)
on Date

SYMBOL LEVEL SEVERITY NO DOCUMENTS IMPACTED BY THIS FMEA(Applicable documents mark as √)

CRITICAL 9 & 10 CONTROL PLAN CTQ

NOTE:-SPECIAL CHARACTERISTICS IDENTIFICATION x SEVERE 6, 7 & 8 BOM OQC Checklist
NO SYMBOL LOW 1 T0 5 SPECIFIC WI PFC
Δ SAFETY 9 & 10 CONTROL PLAN CTQ

Rev. No. DESCRIPTION OF REVISIONS CARRIED OUT DATE Prepared Approved

0 Initial Release 12.10.2022 Prakash Lalit Kumar
1 Revised for Updated Drawing 03.05.2025 Abhishek Lalit Kumar

Approved By: (NPD Head)

Prepared By: ( Executive - NPD) Reviewed By: (AM - QA) Reviewed By: (Supervisor/HOD-Prod.)
Sign:
Sign: Sign: Sign: Name: Mr Lalit Kumar
Name: Mr. ABHISHEK Name: Mr. ALOK Name: Mr.Jay Kishan Date: 03.05.2025
Date: 03.05.2025 Date: 03.05.2025 Date: 03.05.2025

Page 39 of 39