FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)
Project: DAIMLER Part No. :-
Team Leader: DAIMLER Part Name :-
Team Members:
Occurrence
Detection
Severity
Potential Cause(s) of
Op. No. Process Function Potential Failure Mode Potential Effect(s) of Failure Current Controls RPN
Failure
Incomplete
On product: product can be reject Varification of Mill TC
information to
10 Raw Material receiving Wrong grade of material reeived On next process:none 5 2 with p.o. provided to 3 30
supplier about raw
At customer's end:part can be reject supplier
material grade
Incoming inspection
Wrong material composition & not done / unskilled
On product: product can be reject
Grade recived according to inspector lack of sample to be send to third
DAIMLER Raw material standard- On next process:none 5 2 3 30
knowldege to party spectro
E-500 At customer's end:part can be reject
comapre mill tc with
std
On product: product can be reject
part not varified at incoming inspection's
thickness variation On next process:part get burn 8 3 3 72
supplier's end reports
At customer's end:part can be reject
On product: none
incoming inspection's
length variation next process:more scrap will generate 2 supplier negligency 2 3 12
reports
At customer's end:delivery failure
IN-COMING
20 On product: none
INSPECTION incoming inspection's
width variation next process:more scrap will generate 2 supplier negligency 2 3 12
reports
At customer's end:delivery failure
On product: none proper storage not
quality alert have been
rusty sheet On next process:machine will get damage 9 avilable at supplier 3 2 54
displayed
At customer's end:part gets reject end
On product: product can be reject
material handling was quality alert have been
sheet having dent and scraches On next process:none 5 2 3 30
not proper displayed
At customer's end:part can be reject
visual aids and incoming
On product: product can be reject standard desplayed near
pitted sheet On next process:none 5 supplier negligency 2 incoming area , incoming 2 20
At customer's end:part can be reject report to be sign off by
quality head
On product: material got rusty or pitted
Material stored in open hence reject Material Loacation not Material storage is in racks
conditiion
7
defined.
2
with covering in Storage area.
2 28
On next process:none
At customer's end:part can be reject
On product: product can be reject due to
wrong grade use Material location not Racks are Identified as per grade
30 Storage material in Mix up condition 6 Identified 2 and thickness wise. 2 24
On next process:none
At customer's end:part can be reject
On product:tracibility will not done
Material not stored as per FIFO On next process:none 5 Wrong colour coding 2 Daily Stock Board 2 20
At customer's end:none
[Link] may not fit during assembly.
1. Sheet Flatness Not ok 1st and last 5 pcs approval by
[Link] may not qulalifing in Rec. gauge if assembly
2. operator and Inprocess
Slot Shifted done. [Link]/Process 6 Program Editing. 3 Inspector /Inprocess Insopection 2 36
Function May affects and part will be reject at cutomer
[Link] Not clamped Report
end.
[Link] may not fit in assembly. 2 Inprocess Inspection by 1st 5 pcs
Assembly may reject if part will assembled. Diaa Puntch offset approval or increase the ac offset
Hole Dia Under size
3. Product performanec may affects if part will 7 Distrubed 3 in program during first part 3 63
fit at customer end approval
[Link] May not fit during assembly
Diaa Puntch offset
Heavy burrs on profile [Link] quality affects if Part assembled 6 Distrubed 3 Daily process check sheet 3 54
[Link] visually Reject at customer end if delivered
[Link] may not fit in assembly. 2 Inprocess Inspection by 1st 5 pcs
Assembly may reject if part will assembled. Diaa Puntch offset approval or decrease the ac offset
Hole Dia Over size
3. Product performanec may affects if part will 7 Distrubed 3 in program during first part 3 63
fit at customer end approval
1. Part cutting may not complete if machine will
[Link] maintenance plan
suddenly Stopped. [Link] may be
[Link] maintenance available.
Machine Breakdown delayed and Delivery scheduled may not meet. 5 Not done 2. 3 [Link] plan made for 3 45
[Link] parameter may be
Breakdown of laser machine
disturbed
Two Inprocess Inspectors are
Inprocess Inspector absency Defective part could be move to next operation 6 Inspection Not Done 2 available for laser cut Part 2 24
Inspection.
50 Inprocess Inspection
sample inspection with template /
Ng part get passed from in-process Inspection Not Done ,
inspection
Wrong part produced , customer rejection 6 master sample wear 2 master sample ,Validate master 2 24
sample once in a year
On product:part rejects
On next process:part reject first part approvel not done
60 final inspection part not qualified in receiving gauge 5 in bending 2 100% inspection to be done 2 20
At customer's end:part reject & customer
dissatisfied
On product:part rejects
On next process:part reject inspection not done at final 100% qualify with reciving
70 Pre dispatch inspection wrong dimension observed 5 stage 3 gauge 2 30
At customer's end:part reject & customer
dissatisfied
On product: material got rusty or pitted
Material stored in open hence reject Material Loacation not Material storage is in racks
conditiion
7
defined.
2
with covering in Storage area.
2 28
On next process:none
At customer's end:part can be reject
On product: delivery failure
On next process:none Material location not Racks are Identified as per grade
80 finish good storage material in Mix up condition 6 Identified 2 and thickness wise. 2 24
At customer's end:line stopage and cutomer
dissatisfied
On product:tracibility will not done
Material not stored as per FIFO On next process:none 5 Wrong colour coding 2 Daily Stock Board 2 20
At customer's end:none
On product:part can be damage during
transpotation instruction about packing
90 packing and dispatch part not pack as per packing standard 5 standard not displayed at 2 display packing instructions 3 30
On next process:none packing area
At customer's end:part: can be reject
PREPARED BY : AMAN GOYAL APPROVED BY : RAM PRASAD
CESS FMEA)
Start Date:
Revised
Recommended Responsibility &
Action(s) Taken
RPN
Occ.
Action(s) Completion Date
Sev.
Det.
VED BY : RAM PRASAD
