Process FMEA

Name : Etech automation Process Responsibility : Mr. Varun dev FMEA Number : FMEA / 26221839
Model Year(s)/Vehicles(s): Key Date: 05.10.2012 Prepared by : Mr. Sethupathi
Core team : Mr.Varun dev, Mr. Vijay, Mr. Ramesh, Mr. Ragavan Part Name : Terminal Bending FMEA Date (orig) : 08.09.12 01
Process Function S C O D RPN
Potential Responsibility & Action Results
Current Process Controls Recommende
Machine Product Potential Failure Cause(s)/ Target
Potential Effect(s) of Failure d RPN
Description Characteristics Mode Mechanism Completion
Action(s)
(s) of Failure Prevention Detection Date
Requirements
Terminal Plate inward Press Tools Carbon Content High Not meeting the design 6 Retail Purchase 2 Bulk Purchase Every lot supplier test 6 72
inspection Low carbon sheet requirement. of MS Sheet certificate verification,
(Opn.:10) Sixmonth once external lab
verification
Hole Dia Diameter 5.41 Customer assy Difficult 8 Punch wornout 2 Process control by Incoiming Inspection, 6 96
less than supplier Supplier inspection report
Specification verification

Diametr 5.51 Less Pressing force at 6 Wrong Punch 2 Process control by Incoiming Inspection, 6 72
more than customer End Used supplier Supplier inspection report
specification verification

Distance Distance 49.10 Tilt in 5.46 hole axis 8 Wrong operation 2 Punch hole after incoiming Insp & customer 4 64
less than .Assembly problem in sequence bending end.
specification customer end
Distance 49.30 Tilt in 5.46 hole axis 8 Wong operation 2 Punch hole after Incoiming Inspection, 4 64
more than .Assembly problem in sequence and bending ( positive Supplier inspection report
specification customer end location. location) verification

Terminal plate -Storage 1.Raw material 1.production line disturbed 6 Storage and 2 Work instruction/ Storage area layout and 5 60
(Opn :20) damage, 2. Not meet individual spec packing method Bins & Racks for periodic Assessment
Scrathes variation proper storing

Stud- Inward inspection Trub & Thread M6 Thread Nogo Thread slip with nut. 8 Grinding Dia 2 First off Incoming Inspection & 6 96
(Opn.: 30) Rolling Answering, undersize. insprction, Every lot 30nos Screw Ring
Major dia 5.85 Process gauge checking
less than monitoring by
specification supplier.

Go Tight Major Difficult to assemble nut. 8 Grinding Dia 2 First off Incoming Inspection & 6 96
dia 5.95 more Oversize. insprction, Every lot 30nos Screw Ring
than Process gauge checking.
Specification monitoring by
supplier.

Shank Dia Diameter 6.0 Offset in assembly brazing 8 Tool Blunt 2 Process control by Incoming inspection, 6 96
less than as well in Moulding. supplier Supplier Report verification
specification Customer end assembly
problem

1.Raw material 1.production line disturbed 6 Storage and 2 Work instruction/ Storage area layout and 5 60
damage, 2. Not meet individual spec packing method Bins & Racks for periodic Assessment
Scrathes variation proper storing

Diameter 6.0 Offset in assembly brazing 8 Wrong Setting 2 Process control by Incoming inspection, 6 96
more than as well in Moulding. supplier Supplier Report
Specification Customer end assembly verification&During Assy.,
problem Torque test (Supplier) After
Brazing
Stud -Storage 1.Raw material 1.production line disturbed 6 Storage and 2 Work instruction/ Storage area layout and 5 60
(Opn :40) damage, 2. Not meet individual spec packing method Bins & Racks for periodic Assessment
Scrathes variation proper storing
 Process FMEA
Name : Etech automation Process Responsibility : Mr. Varun dev FMEA Number : FMEA / 26221839
Model Year(s)/Vehicles(s): Key Date: 05.10.2012 Prepared by : Mr. Sethupathi
Core team : Mr.Varun dev, Mr. Vijay, Mr. Ramesh, Mr. Ragavan Part Name : Terminal Bending FMEA Date (orig) : 08.09.12 01
Process Function S C O Current Process Controls D RPN Responsibility & Action Results
Potential Recommende
Machine Product Potential Failure Target S O D RPN
Potential Effect(s) of Failure Cause(s)/Mechan d Actions
Description Characteristics Mode Completion
ism(s) of Failure Prevention Detection Action(s) Taken
Requirements Date
Brazing Rod- Inward Silver content in Above 50% Brazing Strength will be low wrong Setting Process control by Every lot supplier test
inspection Brazing rod and we will not achive supplier certificate verification,
(Opn :50) torque Sixmonth once external lab
verification.

Brazing Rod -Storage 1.Brazing rod 1.production line disturbed 6 Storage and 2 Work instruction/ Storage area layout and 5 60
(Opn.: 60) damage, 2. Not meet individual spec packing method Bins & Racks for periodic Assessment
variation proper storing

Terminal Assy Inward Torch brazing and Brazing Strength Torque Min Screw broken at end 8 Insufficient 2 10 Nos of lot to Incoming inspection, 6 96
inspection fixture. 10NM Less than customer .Does not meet Brazing be tested for Supplier report verification
(Opn.: 80) specification the customer Requirement Torque.

8 No brazing. 2 Manual Operation Incoming inspection, 6 96

at supplier End. Supplier report verification

8 One side Brazing 2 Manual Operation Incoming inspection, 6 96

at supplier End. Supplier report verification

Distance less Does not locate in moulding 8 Brazing fixture 2 First off & Last off Incoming inspection, 6 96
then 62.50 than Tool. location Pin inspection Supplier report verification
specification Assembly problem in problem
customer end
Pitch Distance
Distance less Does not locate in moulding 8 Brazing fixture 2 First off & Last off Incoming inspection, 6 96
then 62.70 than Tool. location Pin inspection Supplier report verification
specification Assembly problem in problem
customer end

Termial Assy. -Storage 1.Terminal Assy 1.production line disturbed 6 Storage and 2 Work instruction/ Storage area layout and 5 60
(Opn.: 90) bend&damage, 2. Not meet individual spec packing method Bins & Racks for periodic Assessment
variation proper storing

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 Process FMEA
Name : Etech automation Process Responsibility : Mr. Varun dev FMEA Number : FMEA / 26221839
Model Year(s)/Vehicles(s): Key Date: 05.10.2012 Prepared by : Mr. Sethupathi
Core team : Mr.Varun dev, Mr. Vijay, Mr. Ramesh, Mr. Ragavan Part Name : Terminal Bending FMEA Date (orig) : 08.09.12 01
Process Function S C O Current Process Controls D RPN Responsibility & Action Results
Potential Recommende
Machine Product Potential Failure Target S O D RPN
Potential Effect(s) of Failure Cause(s)/Mechan d Actions
Description Characteristics Mode Completion
ism(s) of Failure Prevention Detection Action(s) Taken
Requirements Date
Plated Terminal screw assy Black Spots & Poor appreance and rust in 7 Poor plating Work instruction, Supplier inspection report , 7 98
inward inspection Discolouration terminal screw assy process Supplier process Inward inspection, Once in
(Opn.: 110) audit six month external lab
verification

Plating thickness Go gauge will Difficult to assemble nut 7 Poor plating Work instruction, Supplier inspection report , 7 98
is above 10 not answering. process Supplier process Inward inspection, Once in
micron audit six month external lab
verification

Plated Termial Assy. -Storage 1.Terminal Assy 1.production line disturbed 6 Storage and 2 Work instruction/ Storage area layout and 5 60
(Opn.: 120) bend&damage, 2. Not meet individual spec packing method Bins & Racks for periodic Assessment
variation proper storing

Raw material-Inward Moulding Material 1.component 1.production line disturbed 6 Storage and 2 Work instruction/ Work instruction/ Bins & 5 60
Inspection Phenolic T355J damage 2. Not meet individual spec packing method Bins & Racks for Racks for proper storing
(Opn.: 130) 2.shelf life 3.shrinkage proper will variation proper storing
occurs

Moulding material -Storage 1. Self life Production line disturbed/ 6 Improper storage 2 Material Trays, Bins with 5 60
(Opn :140) detoriation Function fitment failure and packing Identification Identification/ Storage
method not system through area layout
followed as per Work Instruction/
Work Instruction FIFO
Terminal Moulding Moulding. Pip diameter Difficult to assemble cover 6 and wornout
Die FIFO 2 None First off & Last off inspection 6 72
(Opn.:150) 6.50 more than
specification

Pip Inner Pip diameter Difficult to assemble cover 6 Improper 2 100 % inspection First off & Last off inspection 6 72
Diameter 6.30 less than de- flashing .
specification

Moulding. Diameter Difficult to assemble with 8 Cavity oversize 2 None First off inspection & Last off 5 80
8.20 less than housing & Will Break inspection
specification PDQA Report
Outer Dia

Flashes on Difficult to assemble 8 Improper 2 None 100 % visual inspection, 6 96

inner Dia deflashing PDQA Report
Inner Dia(5.46)

8 Improper Brazing 2 Work instruction, Sample basis Toque test to 6 96

& Moulding Supplier process be done.
Production line disturbed/ audit
Torque Min 10 Nm Function fitment failur,
Customer dissatsification

Flashes Nut assy difficult , may 8 Improper 2 None 100 % visual inspection, 6 96
result poor electrical deflashing PDQA Report
M6 Thread contact

Deflashing Flashes on Difficult in assembly and 8 Improper deflash 2 Monitor mould 100 % Deflashing & Visual 5 80
parting line Welding failure cleaning wear inspection
(Opn : 160) area, inner dia
Flashes and outer dia,in
thread.

Visual inspection Short Customer dissatsification 8 Untrained 2 Pre despatch 100% inspection at Final 7 112
(Opn.:170)&(Opn.:180) moulds,cracks, operator / quality audit inspection,
Bobbles, Inspector plan , Training to Pre-despatch inspection
terminal Inspectors, report
damages Periodical
calibration of
IMTE
Visual inspection Pre despatch 100% inspection at Final
(Opn.:170)&(Opn.:180) quality audit inspection,
plan , Training to Pre-despatch inspection
Inspectors, report
Periodical
calibration of
IMTE
Dimension Fitment problem at 8 IMTE Variation 2 7 112
variation customer end

Packing Quantity Customer dissatsification 6 Improper 1 Work instruction / 100% Quantity checking 7 42
(Opn.:190) variation Counting of Visual Aids
packing method
Wrong Part Customer dissatsification 6 Communication 1 Invoicing based Verification of Packed 6 36
Supplied gap on PDQR quantity with Job Card
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