POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS

Part Number 20014107 Rev. I Process Responsibility Mr. Shibu John FMEA Number SMPL/PFMEA/TAURUS-51 Rev. No 0

Part Name Front Latch Key Date 22.12.2022 Prepared By Mr. Vilas Mohurle

Core Team SJ, VM, AB, SKS, RJ Customer Name Taurus FMEA Date (Orig) 25.12.2022

Responsibility Action Results

Recomme
Process Potential Failure Potential Cause(s) / Current Process Control Current Process & Target
Operation Requirement Potential Effect(s) of Failure Sev. Class Occ. Det. RPN nded
No. Mode mechanism (s) of Failure Prevention Controls Detection Completion Actions
Action(s) Sev Occ Det RPN
Date Taken
1. Mill TC
Quality plan not followed
NP - Nil veification at
by supplier
receipt stage
Wrong Material 2. Third party
SP - Nil Material procurement from
AISI 416 - NTT 155 receipt / Improper 6 3 material test 6 108
approved source
Material
CE - Part Failure

EU - Less part life

As per ASTM
Inclusion NP- Nil
NTT155
140 - 200 HB SP- Tool may break the tool in
Hardness
(77.6 to 93.5 HRB) next operation Process SOP not Material procurement from
Reciept 6 3 Receipt Inspecion 6 108
10 Not as per followed by supplier approved source
Inspection Matrix Spheroidized CE-Nil
specifications
Globular and
Carbide EU-Nil
uniformly distributed

Grain size 5 to 8 ASTM E112

NP- May remain unclean in

next operation

Bend, damage, crack SP- Nil Process SOP not Material procurement from
Free from visual surface defects 3 3 Receipt Inspecion 6 54
etc. followed by supplier approved source
CE-Nil

EU-Nil

1. Set up
NP-Nil 1. Setting error 1. Setting work instructions
approval report,
2. Tool change frequency 2. Inprocess
SP- Nil 2. Tool worn out
Oversize 4 3 monitoring Inspection 7 84
3. Wrong offset
CE-Fitment & functional error 3. Work Instruction
correction

Turning and EU-Less part life

20 OD
Parting
Ø 3.50 (-0.02 -0.08) 1. Set up
NP-Nil 1. Setting error 1. Setting work instructions
approval report,
2. Wrong offset 2. Inprocess
SP- Nil 2. Work Instruction
Undersize 4 correction 3 Inspection 7 84
CE-Fitment & functional error

EU-Less part life

 Responsibility Action Results
Recomme
Process Potential Failure Potential Cause(s) / Current Process Control Current Process & Target
Operation Requirement Potential Effect(s) of Failure Sev. Class Occ. Det. RPN nded
No. Mode mechanism (s) of Failure Prevention Controls Detection Completion Actions
Action(s) Sev Occ Det RPN
Date Taken

1. Set up
NP-Nil 1. Setting error 1. Setting work instructions
approval report,
2. Tool change frequency 2. Inprocess
SP- Nil 2. Tool worn out
Oversize 5 3 monitoring Inspection 5 75
3. Wrong offset
CE-Fitment & functional error 3. Work Instruction
correction
EU-Less part life
Total Length 14.4+0.1
1. Set up
NP-Nil 1. Setting error 1. Setting work instructions
approval report,
2. Wrong offset 2. Inprocess
SP- Nil 2. Work Instruction
correction Inspection
Undersize 5 3 5 75
3. Wrong offset
CE-Fitment & functional error 3. Work Instruction
correction

EU - Less part life

1. Set up
NP-Nil 1. Setting error 1. Setting work instructions
approval report,
2. Wrong offset 2. Inprocess
SP- Nil 2. Work Instruction
correction Inspection
Oversize 4 3 5 60
CE- May cause functional and
fitment issue
Turning and EU - Less part life
20
Parting ID
Ø 2.50±0.1 1. Set up
NP-Nil 1. Setting error 1. Setting work instructions
approval report,
2. Tool change frequency 2. Inprocess
SP- Nil 2. Tool worn out
Undersize 4 3 monitoring Inspection 5 60
CE- May cause functional and 3. Wrong offset
3. Work Instruction
fitment issue correction

EU - Less part life

NP-Nil 1. Setting error 1. Setting work instructions

2. Wrong offset
SP-Nil 2. Work Instruction 1. Set up
Oversize 4 correction 3 7 84
3. Tool change frequency approval report,
Customer dissatisfaction 3. Tool worn out
monitoring

EU-Nil
Depth 1±0.1
NP-Nil 1. Setting error 1. Setting work instructions
2. Tool change frequency
SP-Nil 2. Tool worn out
monitoring 1. Set up
Undersize 4 3 6 72
approval report,
CE- Fitment problem in assembly 3.Wrong Tool 3.Tool planning sheet

EU-Nil
 Responsibility Action Results
Recomme
Process Potential Failure Potential Cause(s) / Current Process Control Current Process & Target
Operation Requirement Potential Effect(s) of Failure Sev. Class Occ. Det. RPN nded
No. Mode mechanism (s) of Failure Prevention Controls Detection Completion Actions
Action(s) Sev Occ Det RPN
Date Taken
1. Set up
NP-Nil 1. Setting error 1. Setting work instructions
approval report,
2. Tool change frequency 2. Inprocess
SP- Nil 2. Tool worn out
monitoring Inspection
Oversize 4 3 6 72
3. Wrong offset
CE-Fitment & functional error 3. Work Instruction
correction

EU-Less part life

OD 3.1±0.1
1. Set up
NP-Nil 1. Setting error 1. Setting work instructions
approval report,
2. Tool change frequency 2. Inprocess
SP- Nil 2. Tool worn out
monitoring Inspection
Undersize 4 3 6 72
3. Wrong offset
CE-Fitment & functional error 3. Work Instruction
correction

EU - Less part life

NP-Nil 1. Setting error 1. Setting work instructions

2. Tool change frequency

SP-Nil 2. Tool worn out
monitoring 1. Set up
Oversize 4 3 6 72
3. Wrong offset approval report,
Customer dissatisfaction 3. Work Instruction
correction

EU-Nil
Radius 2 x R0.8
NP-Nil 1. Setting error 1. Setting work instructions

2. Tool change frequency

SP-Nil 2. Tool worn out
monitoring 1. Set up
Profile Angle Undersize 4 3 6 72
30 3. Wrong offset approval report,
Milling CE-Reject 3. Work Instruction
correction

EU-Nil

NP-Nil 1. Setting error 1. Setting work instructions

2. Tool change frequency

SP-Nil 2. Tool worn out
monitoring 1. Set up
Oversize 5 3 6 90
approval report,
CE-Reject

EU-Nil
Dim. 6.1±0.1
NP-Nil 1. Setting error 1. Setting work instructions

2. Wrong offset
SP-Nil 2. Work Instruction
correction 1. Set up
Undersize 5 3 6 90
approval report,
CE- Customer dissatisfaction

EU-Less part life

NP-Nil 1. Setting error 1. Setting work instructions

2. Tool change frequency

SP-Nil 2. Tool worn out
monitoring 1. Set up
Dim. 12.09-0.2 Oversize 5 3 6 90
approval report,
CE-Reject

EU-Nil
 Responsibility Action Results
Recomme
Process Potential Failure Potential Cause(s) / Current Process Control Current Process & Target
Operation Requirement Potential Effect(s) of Failure Sev. Class Occ. Det. RPN nded
No. Mode mechanism (s) of Failure Prevention Controls Detection Completion Actions
Action(s) Sev Occ Det RPN
Date Taken

NP-Nil 1. Setting error 1. Setting work instructions

2. Wrong offset
SP-Nil 2. Work Instruction
correction 1. Set up
Dim. 12.09-0.2 Undersize 5 3 6 90
approval report,
CE- Customer dissatisfaction

EU-Less part life

NP-Nil 1. Setting error 1. Setting work instructions

2. Tool change frequency

SP-Nil 2. Tool worn out
monitoring 1. Set up
Oversize 5 3 6 90
3. Process parameter approval report,
CE-Reject 3. Excess chuck run out
monitoring

EU-Nil
Dim. 1.94±0.1
NP-Nil 1. Setting error 1. Setting work instructions

2. Wrong offset
SP-Nil 2. Work Instruction
correction 1. Set up
Undersize 5 3 6 90
approval report,
CE- Customer dissatisfaction

EU-Less part life

NP-Nil 1. Setting error 1. Setting work instructions

2. Tool change frequency

SP-Nil 2. Tool worn out
Profile Angle monitoring 1. Set up
30 Oversize 5 3 6 90
Milling approval report,
CE-Reject

EU-Nil
Angle 30°
NP-Nil 1. Setting error 1. Setting work instructions

SP-Nil
1. Set up
Undersize 5 3 6 90
approval report,
CE- Customer dissatisfaction

EU-Less part life

NP-Nil 1. Setting error 1. Setting work instructions

2. Tool change frequency

SP-Nil 2. Tool worn out
monitoring 1. Set up
Oversize 4 3 6 72
3. Wrong offset approval report,
Customer dissatisfaction 3. Work Instruction
correction

EU-Nil
Radius 2 x R2
NP-Nil 1. Setting error 1. Setting work instructions

2. Tool change frequency

SP-Nil 2. Tool worn out
monitoring 1. Set up
Undersize 4 3 6 72
3. Wrong offset approval report,
CE-Reject 3. Work Instruction
correction

EU-Nil
 Responsibility Action Results
Recomme
Process Potential Failure Potential Cause(s) / Current Process Control Current Process & Target
Operation Requirement Potential Effect(s) of Failure Sev. Class Occ. Det. RPN nded
No. Mode mechanism (s) of Failure Prevention Controls Detection Completion Actions
Action(s) Sev Occ Det RPN
Date Taken

NP-Nil 1. Setting error 1. Setting work instructions

2. Tool change frequency

SP-Nil 2. Tool worn out
monitoring 1. Set up
Oversize 4 3 6 72
3. Wrong offset approval report,
Customer dissatisfaction 3. Work Instruction
correction

EU-Nil
Radius 2 x R1
NP-Nil 1. Setting error 1. Setting work instructions

2. Tool change frequency

SP-Nil 2. Tool worn out
monitoring 1. Set up
Undersize 4 3 6 72
3. Wrong offset approval report,
CE-Reject 3. Work Instruction
correction

EU-Nil

NP-Nil 1. Setting error 1. Setting work instructions

2. Tool change frequency

SP-Nil 2. Tool worn out
monitoring 1. Set up
Oversize 5 3 6 90
3. Process parameter approval report,
CE-Reject 3. Excess chuck run out
monitoring

EU-Nil
Dim. 0.9-0.1
NP-Nil 1. Setting error 1. Setting work instructions

2. Wrong offset
SP-Nil 2. Work Instruction
correction 1. Set up
Undersize 5 3 6 90
approval report,
CE- Customer dissatisfaction

EU-Less part life

Profile Angle
30
Milling
NP-Nil 1. Setting error 1. Setting work instructions

2. Tool change frequency

SP-Nil 2. Tool worn out
monitoring 1. Set up
Oversize 5 3 6 90
approval report,
CE-Reject

EU-Nil
Angle 40°
NP-Nil 1. Setting error 1. Setting work instructions

SP-Nil
1. Set up
Undersize 5 3 6 90
approval report,
CE- Customer dissatisfaction

EU-Less part life

NP-Nil 1. Setting error 1. Setting work instructions

2. Tool change frequency

SP-Nil 2. Tool worn out
monitoring 1. Set up
Oversize 5 3 6 90
3. Process parameter approval report,
CE-Reject 3. Excess chuck run out
monitoring

EU-Nil
Thickness 2±0.1
NP-Nil 1. Setting error 1. Setting work instructions

2. Wrong offset
SP-Nil 2. Work Instruction
correction 1. Set up
Undersize 5 3 6 90
approval report,
CE- Customer dissatisfaction

EU-Less part life

 Responsibility Action Results
Recomme
Process Potential Failure Potential Cause(s) / Current Process Control Current Process & Target
Operation Requirement Potential Effect(s) of Failure Sev. Class Occ. Det. RPN nded
No. Mode mechanism (s) of Failure Prevention Controls Detection Completion Actions
Action(s) Sev Occ Det RPN
Date Taken

NP-Nil 1. Setting error 1. Setting work instructions

2. Tool change frequency

SP-Nil 2. Tool worn out
monitoring 1. Set up
Oversize 5 3 6 90
approval report,
CE-Reject

EU-Nil
Dim. 13.89-0.05
NP-Nil 1. Setting error 1. Setting work instructions

2. Wrong offset
SP-Nil 2. Work Instruction
correction 1. Set up
Undersize 5 3 6 90
approval report,
CE- Customer dissatisfaction

EU-Less part life

Profile Angle
30
Milling
NP-Nil 1. Setting error 1. Setting work instructions

2. Tool change frequency

SP-Nil 2. Tool worn out
monitoring 1. Set up
Oversize 5 3 6 90
3. Process parameter approval report,
CE-Reject 3. Excess chuck run out
monitoring

EU-Nil
Thickness 2-0.1
NP-Nil 1. Setting error 1. Setting work instructions

2. Wrong offset
SP-Nil 2. Work Instruction
correction 1. Set up
Undersize 5 3 6 90
approval report,
CE- Customer dissatisfaction

EU-Less part life

Stage
40 100% Inspection by measuring instruments and gauges
Inspection

HT process parameter Process parameter

NP-Nil
disturbed at supplier monitoring

SP-Nil Incorrect inspection Skill matrix of inspector

High 5 3 Test report 6 90
CE-Reject Hardness tester error Calibration frequency

EU-Nil
Heat
50 Hardness 34-44 HRC
Treatment HT process parameter Process parameter
NP-Nil
disturbed at supplier monitoring

SP-Nil Incorrect inspection Skill matrix of inspector

Low 5 3 Test report 6 90
CE-Reject Hardness tester error Calibration frequency

Process SOP not

EU-Less part life HT SOP
followed by supplier
 Responsibility Action Results
Recomme
Process Potential Failure Potential Cause(s) / Current Process Control Current Process & Target
Operation Requirement Potential Effect(s) of Failure Sev. Class Occ. Det. RPN nded
No. Mode mechanism (s) of Failure Prevention Controls Detection Completion Actions
Action(s) Sev Occ Det RPN
Date Taken
Process SOP not
NP-Improper Passivation Work Instruction
followed

Surface SP-Nil Incorrect bead size Verification of bead size

Visual inspection
60 Blasting texture Evenly blasted Incorrect 6 3 6 108
report
(RD 215-107) CE-Reject

EU-Nil

Process SOP not

NP-Nil Work Instruction
followed

Process parameter Process parameter

SP-Nil
disturb monitoring
Surface Finish Roto Finish Incorrect finish 6 3 6 108
CE-Reject

EU-Less part life Visual inspection

70 Passivation
report
Process SOP not
NP-Nil Work Instruction
followed
Process parameter Process parameter
SP-Nil
Free from surface Presence of surface disturb monitoring
Visual 5 3 6 90
defects defects
CE-Reject Incorrect handling

EU-Less part life

Final
80 100% Inspection by measuring instruments and gauges
Inspection

Excess qty. packing Customer dissatisfaction 6 2 6 72

Short qty.packing Customer dissatisfaction 6 2 6 72

Packing SOP not Packing
90 Packing Qty. per box, Packing slip Packing SOP
followed verification visually
Wrong part packing Customer dissatisfaction 8 2 6 96

Packing slip missing Customer dissatisfaction 4 2 6 48

Prepared By: A Gokhe Apprved By:- V Mohurle