Doc.

No

PFMEA (Process Failure Mode Effect Analysis) Owner team

Part Part name (Part No.) Owner

Program Comp. date Initiate date
CF Team Rev. date

Rev. CFTeam
(Contents)
No. (Date)
MFG PROD QUALITY
 FAMILY OF PARTS: Pinion Housings

Item (Part #): 38xxxxxxx _ Rev 03 MPC

Model Year/Program

Core Team:

Process

Severity
Step Potential Potential
Roadmap
Requirements Failure Effect(s)
No.
Mode of Failure
Function

Colour variation and breakage on

D1 # 01 Receipt of Raw Material. Wrong matl.received 4
the part

Incoming inspection of raw Component cracked

D1 # 02 Mix up of granules with other materials 4
material visual defects

Components fails , rejected by

#03 Storage of raw material Use of wrong material 4
customer end/ line stoppage

Customer disatisfaction due to

Mix up of previous raw material (different grades) 4
rejection
Loading of raw material in
D1 #04
bin
 Process

Severity
Step Potential Potential
Roadmap
Requirements Failure Effect(s)
No.
Mode of Failure
Function

Loading of raw material in

D1 #04
bin
Customer disatisfaction due to
Contaimation during loading of RM 4
rejection

Colour Difference Aesthetics 4

#05 Purging Degraded or burnt material Change in material properties 5

Mixed material of two different grades Change in material properties 5

Short Fill component will be broken 3

component will be rejected in visual

Burnt Mark 3
inspection

Silver Streak component will be rejected 3

 Process

Severity
Step Potential Potential
Roadmap
Requirements Failure Effect(s)
No.
Mode of Failure
Function

dimensional deviation &

Warpage 3
componenet will be rejected

dimensional deviation &

Shrinkage 3
componenet will be rejected

Breakage component will be rejected 3

#06 Injection Moulding

Flow Line Component will be broken 3

Velocity / Speed
Shot Moukd & Shrink Mark 4
< 45%
Velocity / Speed
More flash & Burnt mark 4
> 65%
Injection Pressure
Shot Mould 4
< 90 Bar
Injection Pressure
Over Flash & Over dimension. 4
>110Bar
Inj Time < 1.00sec Shrinkage & Short Mould 4

Inj Time > 3.00 sec Over Flash 4

Zone 1 Temp. <180° c

Component sticking & Part filling
Zone 2 Temp. < 175° c 4
problem.
Zone 3 Temp. < 170° c
 Process

Severity
Step Potential Potential
Roadmap
Requirements Failure Effect(s)
No.
Mode of Failure
Function

Zone 1 Temp. >200° c

Zone 2 Temp. > 195° c Degrade, Breakage, Burnt Mark. 4
Zone 3 Temp. > 190° c

Dimensional variation Rejection 1

Variation in Ball pin side diameter20.50± 0.50 - <

A3 Assembly issue 1
20.00

Variation in Ball pin side diameter20.50± 0.50 - >

A3 Assembly issue 1
20.50

Variation in Diameter - 50.2±0.5

C3 Assembly issue 1
< 49.70

Variation in Diameter - 50.2±0.5

C3 Assembly issue 1
> 52.70
 Process

Severity
Step Potential Potential
Roadmap
Requirements Failure Effect(s)
No.
Mode of Failure
Function

Variation in Diameter - 57.2±0.5

C3 Assembly issue 1
< 56.70

Variation in Diameter - 57.2±0.5

C3 Assembly issue 1
> 57.70

Variation in Height -88.0+0.1-0.40

B4 Assembly issue 1
> 87.60

Variation in Height -88.0+0.1-0.40

B4 Assembly issue 1
< 89.00

Variation in Pull of load - 30 ~70N

D2 Assembly issue 1
> 30 N
 Process

Severity
Step Potential Potential
Roadmap
Requirements Failure Effect(s)
No.
Mode of Failure
Function

Variation in Pull of load - 30 ~70N

D2 Assembly issue 1
< 70 N

Variation in Roundness - 2.0±0.5

B2 Assembly issue 1
> 1.50

Variation in Roundness - 2.0±0.5

B2 Assembly issue 1
< 2.50

Variation in Roundness - 3.00 ± 0.50

B2 Assembly issue 1
> 2.50

Variation in Roundness - 3.00 ± 0.50

B2 Assembly issue 1
< 3.50

B2 Variation in Wall thickness - 1.10 Assembly issue 1

 Process

Severity
Step Potential Potential
Roadmap
Requirements Failure Effect(s)
No.
Mode of Failure
Function

C2 Variation in Wall thickness - 1.50 Assembly issue 1

C2 Variation in Roundness - 0.50 max Assembly issue 1

Variation in Diameter - 44.5±0.5

C3 Assembly issue 1
>44.00
#07 First off @ every start up

Variation in Diameter - 44.5±0.5

C3 Assembly issue 1
< 45.00

C4 Variation in Thickness - 2.00 Assembly issue 1

Variation in Height - 56.5±0.5

B4 Assembly issue 1
> 56.00
 Process

Severity
Step Potential Potential
Roadmap
Requirements Failure Effect(s)
No.
Mode of Failure
Function

Variation in Height - 56.5±0.5

B4 Assembly issue 1
< 57.00

Variation in Height - 43±0.5

A3 Assembly issue 1
> 42.50

Variation in Height - 43±0.5

A3 Assembly issue 1
< 43.50

B3 Variation in Roundness - 5.00 Assembly issue 1

Variation in Thickness - 1.5-0.2

C5 Assembly issue 1
>1.30

Variation in Thickness - 1.5-0.2

C5 Assembly issue 1
< 1.50
 Process

Severity
Step Potential Potential
Roadmap
Requirements Failure Effect(s)
No.
Mode of Failure
Function

C6 Variation in Distance - 0.4 Assembly issue 1

C8 Variation in Diameter - 10.00 Assembly issue 1

C8 Variation in Diameter - 10.70 Assembly issue 1

Variation in Diameter - 18.30 ± 0.50

B8 Assembly issue 1
> 17.80

Variation in Diameter - 18.30 ± 0.50

B8 Assembly issue 1
< 18.80

B6 Variation in Roundness - 3.00 Assembly issue 1

 Process

Severity
Step Potential Potential
Roadmap
Requirements Failure Effect(s)
No.
Mode of Failure
Function

B6 Variation in Roundness - 0.40 Assembly issue 1

B8 Variation in Angle -120° Assembly issue 1

Variation in Height - 74±0.5

B4 Assembly issue 1
> 73.50

Variation in Height - 74±0.5

B4 Assembly issue 1
< 74.50

Visual defects Rejection 1

#08 Inprocess inspection Dimensional variation in the component Wrong part of dimension 1

REJECTION 1
DIMENSIONAL VARIATION AND VISUAL
#09 LAST OFF INSPECTION
DEFECTS
REJECTION 1
 Process

Severity
Step Potential Potential
Roadmap
Requirements Failure Effect(s)
No.
Mode of Failure
Function

Short moulding, Silver strekes, Flow lines, Burnt

#10 Post - moulding operation. mark, Flash, Voids, War page, Shrinkage & Component will be rejected 1
Breakage

Dimensional variation Fitment problem 1

#11 Final inspection Visual defects, No short fill, No shrinkage, No

burnt mark, No rib cut, No war page, No Customer compliant 1
moisture mark, Gate point flash

Wrong labeling Line stoppage 4

#12 Packing/ Labelling
Less quantity of products packed. Line stoppage 4

Storage
#13 no identification on box component to be hold 4
(at dispatch area)

#14 Dispatch to Customer Inter change of identification stickers on boxes Component to be hold 4
 Process

Severity
Step Potential Potential
Roadmap
Requirements Failure Effect(s)
No.
Mode of Failure
Function
 Process

Severity
Step Potential Potential
Roadmap
Requirements Failure Effect(s)
No.
Mode of Failure
Function
 Process

Severity
Step Potential Potential
Roadmap
Requirements Failure Effect(s)
No.
Mode of Failure
Function
 Process

Severity
Step Potential Potential
Roadmap
Requirements Failure Effect(s)
No.
Mode of Failure
Function
 Process

Severity
Step Potential Potential
Roadmap
Requirements Failure Effect(s)
No.
Mode of Failure
Function
 Process

Severity
Step Potential Potential
Roadmap
Requirements Failure Effect(s)
No.
Mode of Failure
Function
 Process

Severity
Step Potential Potential
Roadmap
Requirements Failure Effect(s)
No.
Mode of Failure
Function
 Process

Severity
Step Potential Potential
Roadmap
Requirements Failure Effect(s)
No.
Mode of Failure
Function
 Process

Severity
Step Potential Potential
Roadmap
Requirements Failure Effect(s)
No.
Mode of Failure
Function
 Process

Severity
Step Potential Potential
Roadmap
Requirements Failure Effect(s)
No.
Mode of Failure
Function
 Process

Severity
Step Potential Potential
Roadmap
Requirements Failure Effect(s)
No.
Mode of Failure
Function
 Process

Severity
Step Potential Potential
Roadmap
Requirements Failure Effect(s)
No.
Mode of Failure
Function
 Process

Severity
Step Potential Potential
Roadmap
Requirements Failure Effect(s)
No.
Mode of Failure
Function
 Process

Severity
Step Potential Potential
Roadmap
Requirements Failure Effect(s)
No.
Mode of Failure
Function
 POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS
(PROCESS FMEA)

Process Responsibility

Key Date
ation
Clas
sific

Occurrence
Current
Potential
Process
Causes(s)
Controls
of Failure
Prevention

Material grade, code & batch not matching Material name, grade & colour identification on the
3
with specification bag should be mentioned

1) Improper storage
1) Proper storage
2) Open bags 2 2) Closed / sealed bags
3) Proper identification
3) With out identification

1) Wrong Identification
2 1) Identification on the bags
2) Usage of wrong material

As per Material change procedure (Centralised RM

Previous running RM not cleaned properly. 2
loading system)
ation
Clas
sific

Occurrence
Current
Potential
Process
Causes(s)
Controls
of Failure
Prevention

Dust/dirt on the surface of bag entered into

As per Material change procedure (Centralised RM
the hopper when loading material directly 2
loading system)
from the bag

a) Not cleaned the barrel properly during

change over of same material with different Training the operator to clean the barrel before
colour. 2 starting the process & purging procedure display
b) Not cleaned the hopper properly during near m/c
change over of material

a) Material changing changing in barrel for Training the operator to clean the barrel before
too long period. 2 starting the process & purging procedure display
b) Set temperature too high . near m/c

a) Not cleaned the barrel properly during

a) Operator awareness & training.
change over of same material with different
b) Visual check up of components during first of
colour. 2
approval.
b) Not cleaned the hopper properly during
c) Visual checking of hopper during loading material
change over of different material

Increase the shot size and check & correct nozzle

less shot size & material leakage in nozzle 4
dia

Air trap & injection speed high 4 Clean the air vent & reduce injection speed

1) Raw material not pre heated properly 1) Set the proper temprature & time for pre heating
3
2) High nozzle tempratue 2) Decrease nozzle temprature
ation
Clas
sific

Occurrence
Current
Potential
Process
Causes(s)
Controls
of Failure
Prevention

1) Less cooling time & blokage in mould 1) Increase the cooling time & clean the mould
cooling line 4 cooling line
2) Non- uniform ejection 2) Inspect & adjust the ejection system

1) Low holding & low injection pressure 1) Increase the holding & injection pressure
4
2) Low injection speed 2) Increase the injection speed

1) High injection pressure 1) Decrease injection pressure

3
2) low mould temprature 2) Increase mould temprature

1) low injection speed 1) Increase injection speed

2) inadequate cycle time 4 2) Increase the cycle time
3) low mould temprature 3) Increase the mould temprature

Setting parameter not as per standard 1) Check the process.

3
parameter 2) Increase the velocity.
Setting parameter not as per standard 1) Check the process.
2
parameter 2) Decrease the speed
1) Wrong Identification 1) Check the process.
3
2) Usage of wrong material 2) Decrease the speed
Setting parameter not as per standard 1) Check the process.
3
parameter 2) Decrease the injection pressure
Setting parameter not as per standard 1) Check the cooling time.
3
parameter 2) Increase the cooling time.
Setting parameter not as per standard 1) Check the cooling time.
2
parameter 2) Decrease the cooling time.
1) Check for filling of heater.
Setting parameter not as per standard
3 2) Check the temperature & set the proper
parameter
temperature.
ation
Clas
sific

Occurrence
Current
Potential
Process
Causes(s)
Controls
of Failure
Prevention

1) Check for failure of heater.

Setting parameter not as per standard
3 2) Check the temperature & set the proper
parameter
temperature.

1.Preventive maintenance of tool.

Tool wear or process variation 4
2.Process parameter controlled by PLC controller.

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.
ation
Clas
sific

Occurrence
Current
Potential
Process
Causes(s)
Controls
of Failure
Prevention

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.
ation
Clas
sific

Occurrence
Current
Potential
Process
Causes(s)
Controls
of Failure
Prevention

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.
ation
Clas
sific

Occurrence
Current
Potential
Process
Causes(s)
Controls
of Failure
Prevention

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.
ation
Clas
sific

Occurrence
Current
Potential
Process
Causes(s)
Controls
of Failure
Prevention

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.
ation
Clas
sific

Occurrence
Current
Potential
Process
Causes(s)
Controls
of Failure
Prevention

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.
ation
Clas
sific

Occurrence
Current
Potential
Process
Causes(s)
Controls
of Failure
Prevention

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.

1.Preventive maintenance of tool.

Tool wearout or process variation 4
2.Process parameter controlled by PLC controller.

1.Improper inspection by inspectors

3 Training to inspectors on inspection & handling
2.Lack of inspectors skill

Wrong tool used 2 Work instruction & identification of tool

1.Preventive maintenance of tool.

TOOL WEAR OR PROCESS VARIATION 4
2.Process parameter controlled by PLC controller.

1) Wrong Identification
2 Training to inspectors on inspection and handling
2) Usage of wrong material
ation
Clas
sific

Occurrence
Current
Potential
Process
Causes(s)
Controls
of Failure
Prevention

Work instruction for post moulding not Work instruction along with defects samples to be
present & operators are not trained for post 6 displayed and to be followed and training to be
moulding operation given for operator for post moulding operations
Handling of measuring instruments training
Improper handling of part during inspection. 2
provided.

1) Dock audit conducted for every batch

Lack of awareness on defects 4
2) Visual inspection training provided.

Lack of operator knowledge on packing and

3 Inspection standard /Operator skill evaluation.
labeling .

Lack of operator knowledge on packing and

3 Packing standard
labeling .

No identification sticker 3 provide identification sticker with colour code

Manual error 3 Work instruction for operator

ation
Clas
sific

Occurrence
Current
Potential
Process
Causes(s)
Controls
of Failure
Prevention
ation
Clas
sific

Occurrence
Current
Potential
Process
Causes(s)
Controls
of Failure
Prevention
ation
Clas
sific

Occurrence
Current
Potential
Process
Causes(s)
Controls
of Failure
Prevention
ation
Clas
sific

Occurrence
Current
Potential
Process
Causes(s)
Controls
of Failure
Prevention
ation
Clas
sific

Occurrence
Current
Potential
Process
Causes(s)
Controls
of Failure
Prevention
ation
Clas
sific

Occurrence
Current
Potential
Process
Causes(s)
Controls
of Failure
Prevention
ation
Clas
sific

Occurrence
Current
Potential
Process
Causes(s)
Controls
of Failure
Prevention
ation
Clas
sific

Occurrence
Current
Potential
Process
Causes(s)
Controls
of Failure
Prevention
ation
Clas
sific

Occurrence
Current
Potential
Process
Causes(s)
Controls
of Failure
Prevention
ation
Clas
sific

Occurrence
Current
Potential
Process
Causes(s)
Controls
of Failure
Prevention
ation
Clas
sific

Occurrence
Current
Potential
Process
Causes(s)
Controls
of Failure
Prevention
ation
Clas
sific

Occurrence
Current
Potential
Process
Causes(s)
Controls
of Failure
Prevention
ation
Clas
sific

Occurrence
Current
Potential
Process
Causes(s)
Controls
of Failure
Prevention
ation
Clas
sific

Occurrence
Current
Potential
Process
Causes(s)
Controls
of Failure
Prevention
 FMEA Number: PFM 28
S
Prepared by: sindhu

MED FMEA Date (Orig.) 16.05.2017

FMEA Date (Rev.)

Action Results

Detection Zone
Severity Zone

Priority Level
Current Responsibility

Detection

Occurrence
Process Recommended & Target

RPN
Actions

Detection
Severity
Controls Action Completion Taken

RPN
Detection Date & Effective
Date

1. Material colour to be compared with test certificate.

2. Contamination (foreign particles) to be checked visually
8 96 3 2 3
3. Material grade to be compared with grade mentioned in test
certificate or on the material bag.

Raw material to be cross verified to as per preventive action 8 64 3 2 3

1) Material colour to be cross checked where ever it is

applicable.
2) Raw material to be compared with ok (raw material )
samples. 8 64 3 2 3

3) Material grade to be compared with grade mentioned in test

certificate or on the material bag.

Visual 8 64 3 2 3
 Action Results

Detection Zone
Severity Zone

Priority Level
Current Responsibility

Detection

Occurrence
Process Recommended & Target

RPN
Actions

Detection
Severity
Controls Action Completion Taken

RPN
Detection Date & Effective
Date

Visual 8 64 3 2 3

Colour difference in the components & first piece visual

8 64 3 2 3
inspection

1. Bad aesthetics.
8 80 3 2 3
2) Crack component sticking or breakage during assembly

a) Problem in processing
b) Bad aesthetics 8 80 3 2 3
c) Crack or breakage of components

1) Check the shot size & nozzle dia

2) Check the possibility of locking the parameter with 7 84 3 3 3
appropriate passward
1) Check the air vent & injection speed
2) Check the possibility of locking the parameter with 7 84 3 3 3
appropriate passward

1) Check the preheating temprature & time

2) Check the nozzle temprature
7 63 3 3 3
3) Check the possibility of locking the parameter with
appropriate passward
 Action Results

Detection Zone
Severity Zone

Priority Level
Current Responsibility

Detection

Occurrence
Process Recommended & Target

RPN
Actions

Detection
Severity
Controls Action Completion Taken

RPN
Detection Date & Effective
Date

1) Check the cooling time & mould cooling line

2) Check the possibility of locking the parameter with 7 84 3 3 3
appropriate passward
1) Check the holding , injection pressure & speed
2) Check the possibility of locking the parameter with 7 84 3 3 3
appropriate passward
1) Check the injection pressure & mould temprature
2) Check the possibility of locking the parameter with 7 63 3 3 3
appropriate passward

1) Check the injection speed, cycle time & mould temprature

2) Check the possibility of locking the parameter with 7 84 3 3 3
appropriate passward

1) Check the process.

5 60 3 3 3
2) Increase the velocity.
1) Check the process.
5 40 3 3 3
2) Decrease the speed
1) Check the process.
3 36 3 3 3
2) Decrease the speed
1) Check the process.
2 24 3 3 3
2) Decrease the injection pressure
1) Check the cooling time.
3 36 3 3 3
2) Increase the cooling time.
1) Check the cooling time.
3 24 3 3 3
2) Decrease the cooling time.

1) Check for filling of heater.

3 36 3 3 3
2) Check the temperature & set the proper temperature.
 Action Results

Detection Zone
Severity Zone

Priority Level
Current Responsibility

Detection

Occurrence
Process Recommended & Target

RPN
Actions

Detection
Severity
Controls Action Completion Taken

RPN
Detection Date & Effective
Date

1) Check for failure of heater.

2 24 3 3 3
2) Check the temperature & set the proper temperature.

1.Preventive maintenance record.

5 20 3 3 3
2.First off inspection /Patrol inspection report.

Startup part approval.

First off & Inprocess inspection.
Final Inspection 5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once

Startup part approval.

First off & Inprocess inspection.
Final Inspection 5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once

Startup part approval.

First off & Inprocess inspection.
Final Inspection 5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once

Startup part approval.

First off & Inprocess inspection.
Final Inspection 5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once
 Action Results

Detection Zone
Severity Zone

Priority Level
Current Responsibility

Detection

Occurrence
Process Recommended & Target

RPN
Actions

Detection
Severity
Controls Action Completion Taken

RPN
Detection Date & Effective
Date

Startup part approval.

First off & Inprocess inspection.
Final Inspection 5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once

Startup part approval.

First off & Inprocess inspection.
Final Inspection 5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once

Startup part approval.

First off & Inprocess inspection.
Final Inspection 5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once

Startup part approval.

First off & Inprocess inspection.
Final Inspection 5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once

Startup part approval.

First off & Inprocess inspection.
Final Inspection 5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once
 Action Results

Detection Zone
Severity Zone

Priority Level
Current Responsibility

Detection

Occurrence
Process Recommended & Target

RPN
Actions

Detection
Severity
Controls Action Completion Taken

RPN
Detection Date & Effective
Date

Startup part approval.

First off & Inprocess inspection.
Final Inspection 5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once

Startup part approval.

Layout inspection once in a Year
5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once

Startup part approval.

Layout inspection once in a Year
5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once

Startup part approval.

Layout inspection once in a Year
5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once

Startup part approval.

Layout inspection once in a Year
5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once

Startup part approval.

Layout inspection once in a Year
5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once
 Action Results

Detection Zone
Severity Zone

Priority Level
Current Responsibility

Detection

Occurrence
Process Recommended & Target

RPN
Actions

Detection
Severity
Controls Action Completion Taken

RPN
Detection Date & Effective
Date

Startup part approval.

Layout inspection once in a Year
5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once

Startup part approval.

Layout inspection once in a Year
5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once

Startup part approval.

Layout inspection once in a Year
5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once

Startup part approval.

Layout inspection once in a Year
5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once

Startup part approval.

Layout inspection once in a Year
5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once

Startup part approval.

Layout inspection once in a Year
5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once
 Action Results

Detection Zone
Severity Zone

Priority Level
Current Responsibility

Detection

Occurrence
Process Recommended & Target

RPN
Actions

Detection
Severity
Controls Action Completion Taken

RPN
Detection Date & Effective
Date

Startup part approval.

Layout inspection once in a Year
5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once

Startup part approval.

Layout inspection once in a Year
5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once

Startup part approval.

Layout inspection once in a Year
5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once

Startup part approval.

Layout inspection once in a Year
5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once

Startup part approval.

Layout inspection once in a Year
5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once

Startup part approval.

Layout inspection once in a Year
5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once
 Action Results

Detection Zone
Severity Zone

Priority Level
Current Responsibility

Detection

Occurrence
Process Recommended & Target

RPN
Actions

Detection
Severity
Controls Action Completion Taken

RPN
Detection Date & Effective
Date

Startup part approval.

Layout inspection once in a Year
5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once

Startup part approval.

Layout inspection once in a Year
5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once

Startup part approval.

Layout inspection once in a Year
5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once

Startup part approval.

Layout inspection once in a Year
5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once

Startup part approval.

Layout inspection once in a Year
5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once

Startup part approval.

Layout inspection once in a Year
5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once
 Action Results

Detection Zone
Severity Zone

Priority Level
Current Responsibility

Detection

Occurrence
Process Recommended & Target

RPN
Actions

Detection
Severity
Controls Action Completion Taken

RPN
Detection Date & Effective
Date

Startup part approval.

Layout inspection once in a Year
5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once

Startup part approval.

Layout inspection once in a Year
5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once

Startup part approval.

Layout inspection once in a Year
5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once

Startup part approval.

Layout inspection once in a Year
5 20 3 3 3
Part approval during PPAP
Process monitoring 2 hours once

Compulsory approval of first piece by checking all visual

7 21 3 3 3
defetcs for 5 set by Quality & 100% by operator

Recording Actual critical process parameters & tool

5 10 3 3 3
identification in pre control chart

1.Preventive maintenance record.

5 20 3 3 3
2.First off inspection / patrol inspection report.

Compulsory approval of first first piece by checking all

5 10 3 3 3
dimensions for one set as per IQP.
 Action Results

Detection Zone
Severity Zone

Priority Level
Current Responsibility

Detection

Occurrence
Process Recommended & Target

RPN
Actions

Detection
Severity
Controls Action Completion Taken

RPN
Detection Date & Effective
Date

100% visual inspection 9 54 3 3 3

Final inspection report 5 10 3 3 3

Visual checking 9 36 3 3 3

Visual inspection /Packing slip 8 96 3 2 3

Visual inspection /Packing slip 8 96 3 2 3

Ensure before dispatch verification of the boxes 8 96 3 2 3

Cross verification as per identification tag 8 96 3 2 3

 Action Results

Detection Zone
Severity Zone

Priority Level
Current Responsibility

Detection

Occurrence
Process Recommended & Target

RPN
Actions

Detection
Severity
Controls Action Completion Taken

RPN
Detection Date & Effective
Date
 Action Results

Detection Zone
Severity Zone

Priority Level
Current Responsibility

Detection

Occurrence
Process Recommended & Target

RPN
Actions

Detection
Severity
Controls Action Completion Taken

RPN
Detection Date & Effective
Date
 Action Results

Detection Zone
Severity Zone

Priority Level
Current Responsibility

Detection

Occurrence
Process Recommended & Target

RPN
Actions

Detection
Severity
Controls Action Completion Taken

RPN
Detection Date & Effective
Date
 Action Results

Detection Zone
Severity Zone

Priority Level
Current Responsibility

Detection

Occurrence
Process Recommended & Target

RPN
Actions

Detection
Severity
Controls Action Completion Taken

RPN
Detection Date & Effective
Date
 Action Results

Detection Zone
Severity Zone

Priority Level
Current Responsibility

Detection

Occurrence
Process Recommended & Target

RPN
Actions

Detection
Severity
Controls Action Completion Taken

RPN
Detection Date & Effective
Date
 Action Results

Detection Zone
Severity Zone

Priority Level
Current Responsibility

Detection

Occurrence
Process Recommended & Target

RPN
Actions

Detection
Severity
Controls Action Completion Taken

RPN
Detection Date & Effective
Date
 Action Results

Detection Zone
Severity Zone

Priority Level
Current Responsibility

Detection

Occurrence
Process Recommended & Target

RPN
Actions

Detection
Severity
Controls Action Completion Taken

RPN
Detection Date & Effective
Date
 Action Results

Detection Zone
Severity Zone

Priority Level
Current Responsibility

Detection

Occurrence
Process Recommended & Target

RPN
Actions

Detection
Severity
Controls Action Completion Taken

RPN
Detection Date & Effective
Date
 Action Results

Detection Zone
Severity Zone

Priority Level
Current Responsibility

Detection

Occurrence
Process Recommended & Target

RPN
Actions

Detection
Severity
Controls Action Completion Taken

RPN
Detection Date & Effective
Date
 Action Results

Detection Zone
Severity Zone

Priority Level
Current Responsibility

Detection

Occurrence
Process Recommended & Target

RPN
Actions

Detection
Severity
Controls Action Completion Taken

RPN
Detection Date & Effective
Date
 Action Results

Detection Zone
Severity Zone

Priority Level
Current Responsibility

Detection

Occurrence
Process Recommended & Target

RPN
Actions

Detection
Severity
Controls Action Completion Taken

RPN
Detection Date & Effective
Date
 Action Results

Detection Zone
Severity Zone

Priority Level
Current Responsibility

Detection

Occurrence
Process Recommended & Target

RPN
Actions

Detection
Severity
Controls Action Completion Taken

RPN
Detection Date & Effective
Date
 Action Results

Detection Zone
Severity Zone

Priority Level
Current Responsibility

Detection

Occurrence
Process Recommended & Target

RPN
Actions

Detection
Severity
Controls Action Completion Taken

RPN
Detection Date & Effective
Date
 Action Results

Detection Zone
Severity Zone

Priority Level
Current Responsibility

Detection

Occurrence
Process Recommended & Target

RPN
Actions

Detection
Severity
Controls Action Completion Taken

RPN
Detection Date & Effective
Date