FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)

Project: DAIMLER Part No. :-

Team Leader: DAIMLER Part Name :-
Team Members:

Occurrence

Detection
Severity
Potential
Op. Potential Failure
Process Function Potential Effect(s) of Failure Cause(s) of Current Controls RPN
No. Mode
Failure

Incomplete
On product: product can be reject
information to Varification of Mill TC
Raw Material Wrong grade of material On next process:none
10 5 supplier about 2 with p.o. provided to 3 30
receiving reeived At customer's end:part can be
raw material supplier
reject
grade

Incoming
inspection not
Wrong material composition On product: product can be reject
done / unskilled
& Grade recived according to On next process:none sample to be send
DAIMLER Raw material 5 inspector lack of 2 3 30
At customer's end:part can be to third party spectro
standard- E-500 knowldege to
reject
comapre mill tc
with std

On product: product can be reject

On next process:part get burn part not varified incoming
thickness variation 8 3 3 72
At customer's end:part can be at supplier's end inspection's reports
reject
On product: none
next process:more scrap will supplier incoming
length variation 2 2 3 12
generate negligency inspection's reports
At customer's end:delivery failure
IN-COMING On product: none
20
INSPECTION next process:more scrap will supplier incoming
width variation 2 2 3 12
generate negligency inspection's reports
At customer's end:delivery failure
On product: none
On next process:machine will get proper storage
quality alert have
rusty sheet damage 9 not avilable at 3 2 54
been displayed
At customer's end:part gets supplier end
reject
On product: product can be reject
sheet having dent and On next process:none material handling quality alert have
scraches 5 2 3 30
At customer's end:part can be was not proper been displayed
reject
 visual aids and
incoming standard
On product: product can be reject
desplayed near
On next process:none supplier
pitted sheet 5 2 incoming area , 2 20
At customer's end:part can be negligency
incoming report to
reject
be sign off by quality
head
On product: material got rusty or
pitted hence reject Material storage is in
Material stored in open Material Loacation
conditiion
On next process:none 7
not defined.
2 racks with covering in 2 28
At customer's end:part can be Storage area.
reject can be reject
On product: product
due to wrong grade use
Material location not Racks are Identified as per
30 Storage material in Mix up condition On next process:none 6 Identified 2 grade and thickness wise. 2 24
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
1.Part may not fit during assembly.
1. Sheet Flatness Not 1st and last 5 pcs
2.Part may not qulalifing in
ok approval by operator and
Rec. gauge if assembly done.
Slot Shifted
3.Product/Process Function 6 2. Program 3 Inprocess Inspector 2 36
Editing. /Inprocess Insopection
May affects and part will be reject at
3.Sheet Not clamped Report
cutomer end.

1.Part may not fit in assembly. Inprocess Inspection by

2 Assembly may reject if part will 1st 5 pcs approval or
Diaa Puntch offset
Hole Dia Under size assembled. 3. Product 7 Distrubed 3 increase the ac offset in 3 63
performanec may affects if part will fit at program during first part
customer end approval

1.Part May not fit during assembly

2.Product quality affects if Part Diaa Puntch offset
Heavy burrs on profile
assembled 3.Part visually 6 Distrubed 3 Daily process check sheet 3 54
Reject at customer end if delivered

1.Part may not fit in assembly. Inprocess Inspection by

2 Assembly may reject if part will 1st 5 pcs approval or
Diaa Puntch offset
Hole Dia Over size assembled. 3. Product 7 Distrubed 3 decrease the ac offset in 3 63
performanec may affects if part will fit at program during first part
customer end approval
 1. Part cutting may not complete if machine
1.Preventive maintenance
will suddenly Stopped.
1.Preventive plan available.
2.Production may be delayed and Delivery
Machine Breakdown
scheduled may not meet. 5 maintenance Not 3 2.Contigency plan made 3 45
done 2. for Breakdown of laser
3.Machine parameter may be
machine
disturbed

Two Inprocess Inspectors

Defective part could be move to next
Inprocess Inspector absency
operation 6 Inspection Not Done 2 are available for laser cut 2 24
Part Inspection.

50 Inprocess Inspection

sample inspection with

Ng part get passed from in- Inspection Not Done , template / master
process inspection
Wrong part produced , customer rejection 6 master sample wear 2 sample ,Validate master 2 24
sample once in a year

On product:part rejects
part not qualified in receiving On next process:part reject first part approvel not 100% inspection to be
60 final inspection
gauge 5 2 2 20
At customer's end:part reject & done in bending done
customer dissatisfied

On product:part rejects
On next process:part reject inspection not done 100% qualify with reciving
70 Pre dispatch inspection wrong dimension observed 5 at final stage 3 gauge 2 30
At customer's end:part reject &
customer dissatisfied

On product: material got rusty or

pitted hence reject Material storage is in
Material stored in open Material Loacation
On next process:none 7 2 racks with covering in 2 28
conditiion not defined.
At customer's end:part can be Storage area.
reject

On product: delivery failure

On next process:none Material location not Racks are Identified as per
80 finish good storage material in Mix up condition 6 Identified 2 grade 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
part not pack as per packing packing standard not display packing
90 packing and dispatch
standard On next process:none 5 displayed at packing 2 instructions 3 30
At customer's end:part: can be area
reject

PREPARED BY : AMAN GOYAL APPROVED BY : RAM PRASAD

OCESS FMEA)
Start Date:

Revised
Responsibility
Recommended
& Completion Action(s) Taken

Occ.
Sev.

Det.
RPN
Action(s)
Date
OVED BY : RAM PRASAD