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PROCESS FMEA CHECK SHEET
PFMEA NO.: CES/FM/NS/024-00

STATUS S.No CHECK POINTS OK Past Trouble Data(PTD),Drg,Failure Mode on process and Product, Data for Process & Product charactertics, Similar part comparision,(Detection & prevention mechanisim, Assembly Fitments etc. Was the Process FMEA is prepared using based on FMEA Procedure? NOT OK DOCUMENT REFERENCE Comment & Action Required
Doc No. : CES/ENG/F/25 Rev No 0
Responsibility
Target Date
Have all operations affecting customer requirements including fit, functions, durability,governmental regulations and safety been identified and listed sequentially? Were similar part/process FMEAs considered?
Have appropriate corrective actions been planned or taken for high risk priority numbers?
Have appropriate corrective actions been planned or taken high severity number?
Were risk priorities numbers revised when corrective action was completed?
Were high severity numbers revised when design change was completed? Do the effects consider the customer in terms of the subsequent operation, assembly and product? Were customer plant problems used as an aid in developing the Process FMEA?
10
11
Have the cause been described in terms of something that can be corrected or controlled? Where detection is the major factor, have provision been made to control the cause proir to the next operation? Past Trouble Data base considered, feedback ratio occurance matrix Was the Process FMEA prepared by a cross functional team? Has the team taken into account all customer specific requirements,including FMEA methodlogies as show in the current edition of FMEA? Have all operations including subcontracted, or outsourced processes and services been considered? Have historical campaign and warranty data been reviewed and used in the analysis?
12
13
14
15
16
17
Have you applied the appropriate controls to address all of the identified failure modes? Have provisions been made to control the cause of the failure mode prior to subsequent or the next operations?
18
PREPARED BY
APPROVED BY
POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)

Part Name BRKT-RR DOOR GUARD FR RH / LH Part No/ Issue 82182 / 3 - 3BB0A Customer/Model NISSAN/X02B Core Team S.Pandiyan -Engg ,K.Rajesh - Engg ,P.Kumar - QA, S.Arun Kumar - QA, V.Kumar - Press Shop, Ramesh-Weld Shop
RPN(SxOxD) Occur (O) Sever (S)
Process Responsibility: Mfg-Press Shop Approval / Date : Key Date: 7/6/2011
Document Number Date (Org.) Revision No. Date (Rev.)
CES/FM/NS/036 4/4/2010 1 17/02/2011

Action Results
Detect
Occur
Operation Number & Name
Sevr
Prevention
Detection
Action Taken
Correct Chemical / mechanical properties 1.5A. Part receiving at store. Dimensions as per drawing
Chemical & Mechanical properties variation
Next Opn Customer End User Next Opn
Part cannot be used (8) Nil Nil Part cannot be used Nil Nil Crack will develop(7) Low Performance the Vehicle(7) Nil Crack will develop(7) Low Performance the Vehicle(7) Nil Nil Poor appearance (4) 4 Causes Poor Appearance, Does Not Have Impact on Vehicle function, Sorting & Scraping(4) Nil Poor appearance (4) Nil Nil Poor appearance (4) Nil Cant locate properly(5) Nil Nil Nil 5 5 4 4 7 7 8 -8 --
Supplier process variation 2
Material TC verification
Incoming Sample inspection
4 64 -
Supplier Inspection report
Incoming inspection(Test certificate)
4 64 -
Dimensional Variation.
Customer End User Next Opn
High cushion pressure Clearance on the die & Punch 5
Operating Procedure
No Crack
Crack
Customer End User
First off / Patrol/Last Off Inspection - Set up Preventive maintenance of verification. the tool
Engg & QA Process to be stabilised 175 and to be validated & Jul-10 tools to be fine tuned
84
Thinning( Up to 0.3T )minimum Thickness should be 0.8 mm.
Next Opn Thinning Exceeds the Limit Customer ( Thickness less than 0.8 mm) End User Next Opn Customer
High cushion pressure Clearance on the die & Punch 4
Operating procedure Preventive maintenance of the Tool
First off / Patrol/Last Off Inspection - Set up verification.
84
Low Cushion Presure Operating Procedure High Cushion Pressure 4 Improper holding of component( Beading & Blank holder to be checked) Tool set up not done properly( Setting block ) Die and punch clearance. 4 Preventive maintenance of the Tools Operating Procedure Preventive maintenance of the Tools
First off / Patrol/Last Off Inspection Set up Verification 5 80 -
With out Waviness Waviness PTD End User 10.Draw Next Opn No Double Folding Double Folding Customer End User Next Opn No Air Bubbles Air Bubbles Presence Customer
PTD
First off / Patrol/Last Off Inspection 5 80 -
In draw operation air vent hole blocked 3
Preventive maintenance of First off / Patrol/Last Off the Tools Inspection 5 60 -
End User Next Opn With Bottoming Mark(To Ensure Draw Depth) No Bottoming Mark Customer End User Next Opn No Short Trim Short Trim
Tool set up not done properly( Setting block ) Bottoming Mark Insert Worn out 3
Operating Procedure Preventive maintenance Of the Tools
First off / Patrol/Last Off Inspection Set up Verification 5 75 -
First off / Patrol/Last Off Inspection
Proper Location tobe 100 done & Pin Provided to avoid Mis Location
Engg & Die Maint
60
20.Trim
Prepared By Checked By Page 2 of 10
RPN
Operation / Process Function Requirements
Potential Failure Mode
Potential Effect(s) of Failure
Potential Cause(s) / Mechanism (s) of Failure
Det(D)
Class
Current Process Control
Recommended Action(s)
Respons. And Target Date

CES/FM/NS/036 4/4/2010 1 17/02/2011

Action Results
Detect
Occur
Sevr
Prevention
Detection
Action Taken
No Short Trim
Short Trim
Customer End User
Low Performance the Vehicle (5) Nil Nil Dissatisfaction( No functional impact(4) Nil Nil Will reduce the vehicle perormance.(6) Nil Cant rework, 100% to be scraped if all found to be Exceeds Thinning(7) Crack will develop and low performance the Vehicle.(7) Nil Cant locate next operation & Welding Assembly welding at customer not possible. Nil Cant locate next operation & Welding Assembly welding at customer not possible. Nil Cant locate next operation & Welding Cant Locate in Assy. Nil Cant locate next operation & Welding Assembly welding at customer not possible.Nil Nil Poor appearance (4) Nil
Mis location Of the component
Operating Procedure
Proper Location tobe 100 done & Pin Provided to avoid Mis Location
Jul-10
20.Trim Next Opn Burr with in the Limit(Max=0.2mm) Burr Exceeds the limit Customer End User Next Opn Flanging as per Drawing. 30.Flange & Restrike Thinning( Up to 0.3T )minimum Thickness should be 0.8 mm. Flanging not as per drawing. Customer End User Next Opn Thinning Exceeds Customer the Limit End User Next Opn Hole Missing Customer End User Next Opn All hole Open Hole Not Open
PTD
Punch & Die worn Out 4 Improper clearence between punch & die 3 Preventive maintenance of the Tools First off / Patrol/last off Inspection 5 60 -
Tool set up not done properly( Setting block ) 6 Mislocation of component Improper staking in packing High cushion pressure 7 Clearance on the die & Punch 4 3
Operating Procedure Operator training Packing standard. Operating Procedure
First off / Patrol Inspection 5 PDI Inspection. Engg & QA Process to be stabilised 140 and to be validated & Jul-10 tools to be fine tuned 7 4 3 84 90 -
Preventive maintenance of First off / Patrol/Last Off Inspection the tool
No hole( Datum & Customer Fitment )missing
Punch Broken 8 Punch hight variation. Tool set up not done properly( Setting block ) Punch Broken 8 Punch hight variation. Tool set up not done properly( Setting block ) Improper Location 8 3 3 3
Preventive maintenance of First off / Patrol/Last Off the Tools Inspection.
120
Pin to be provided to locate hole in Next Engineeringoperation and Assembly July -2010 operation
72
Customer End User
120
72
Next Opn No hole( Datum & Customer Fitment ) Hole position shift. Customer position shift. PTD End User Next Opn 40. Pierce & Separation No hole missing Hole Missing Customer End User Next Opn No Double Piercing Double Piercing Customer End User
Preventive maintenance of the Tools.
First off / Patrol/Last Off Inspection.
Pin to be provided to locate hole in Next Engineering120 operation and Assembly July -2010 operation
72
Punch Broken 6 Punch hight variation. Tool set up not done properly( Setting block ) Part location/locator improper 4 3 3
90
First off / Patrol/Last Off Inspection Preventive maintenance of the Tools. 5 60 -
Prepared By
Checked By Page 3 of 10
RPN
Det(D)
Class

Part Name BRKT-RR DOOR GUARD FR RH / LH Part No/ Issue 82182 / 3 - 3BB0A
40. Pierce & Customer/Model NISSAN/X02B Separation

RPN(SxOxD)
CES/FM/NS/036 4/4/2010 1 17/02/2011

Action Results
Core Team S.Pandiyan -Engg ,K.Rajesh - Engg ,P.Kumar - QA, S.Arun Kumar - QA, V.Kumar - Press Shop, Ramesh-Weld Shop
Occur (O) Sever (S)
Detect
Occur
Sevr
Prevention
Detection
Action Taken
Next Opn No Scrap Impression Scrap Impression Customer End User Next Opn Burr with in the Burr Exceeds the Limit(Max=0.15mm) limit
PTD PTD
Nil Poor appearance (4) Nil Nil Dissatisfaction( No functional impact(4) Nil
Poke-Yoke
Improper Sie Insert Cleareance , Die Design 4 4 Preventive maintenance of the Tools.
Customer End User
A Critical Characterisitics
PTD
Past Trouble Data
Significant Characterisitics
Recommended Action : If RPN 100 & Severity is 1 to 7 If RPN 80 & Severity is 8 & 9 If RPN > 10 & Severity is 10
Prepared By
RPN
Det(D)
Class

CES/FM/NS/036 4/4/2010 1 17/02/2011

Action Results
Detect
Occur
Sevr
Prevention
Detection
Action Taken
Correct Chemical / mechanical properties 1.5A. Part receiving at store. Dimensions as per drawing
Chemical & Mechanical properties variation
Next Opn Customer End User Next Opn
Part cannot be used (8) Nil Nil Part cannot be used Nil Nil Nil Low Performance the Vehicle (5) Nil Nil Dissatisfaction( No functional impact(4) Nil Nil Matching Part Fouling or Difficult to Assemble (4) Nil Nil Poor appearance (4) Nil Nil Poor appearance (4) Nil Cant rework, 100% to be scraped if all found to be Exceeds Thinning(7) Crack will develop and low performance the Vehicle.(7) Nil Nil Will reduce the vehicle perormance.(6) 6 4 4 4 4 5 8 -8 --
Material TC verification
Incoming Sample inspection
4 64 -
Supplier Inspection report
Incoming inspection(Test certificate)
4 64 -
Dimensional Variation.
No Blank-out(Blank Blank out Profile Cut) 10.Blank
Mis location Of the component
Operating Procedure
75
Punch & Die worn Out Improper clearence between punch & die 3 Preventive maintenance of the Tools First off / Patrol/last off Inspection 5 60 -
Burr with in the Burr Exceeds the Limit(Max=0.15mm) limit
No Uneven Forming ( Forming Height Variation )
Tool set up not done properly( Setting block ) Mis location Of the component 4
Operating Procedure Additional Location Pin Provided to Ensure Proper Position First off / Patrol/Last Off Inspection 5 80 -
Un Even Forming
Improper Hole Locating Pin 3 Preventive maintenance of the Tools & Punch Clearance Checking
First off / Patrol/Last Off Inspection. 5 Check Point Added in PDI First off / Patrol/Last Off Inspection. 5 Check Point Added in PDI 80 60 -
No Hole Oblong
No Hole Oblong
Customer End User
20.Forming Next Opn No Damages Damages Customer End User

PTD PTD
Lack of operator awarness in loading & Unloading 4
Operator Tranning
Thinning( Up to 0.3T )minimum Thickness should be 0.8 mm.
Next Opn Thinning Exceeds Customer the Limit End User Next Opn
High cushion pressure 7 Clearance on the die & Punch 4
Operating Procedure Preventive maintenance of First off / Patrol/Last Off Inspection the tool 5
84
Tool set up not done properly( Setting block ) Mislocation of component 3
Operating Procedure Operator training
First off / Patrol Inspection 5 90 -
Flanging as per Drawing. 30.Flange & Restrike
Flanging not as per drawing.
Customer
Prepared By
RPN
Det(D)
Class

CES/FM/NS/036 4/4/2010 1 17/02/2011

Action Results
Detect
Occur
Sevr
Flanging as per Drawing. 30.Flange & Restrike Thinning( Up to 0.3T )minimum Thickness should be 0.8 mm.
Flanging not as per drawing. End User Next Opn Thinning Exceeds Customer the Limit End User Next Opn Hole Missing Customer End User Next Opn Nil Cant rework, 100% to be scraped if all found to be Exceeds Thinning(7) Crack will develop and low performance the Vehicle.(7) Nil Cant locate next operation & Welding Assembly welding at customer not possible. Nil Cant locate next operation & Welding Assembly welding at customer not possible. Nil Cant locate next operation & Welding Cant Locate in Assy. Nil Cant locate next operation & Welding Assembly welding at customer not possible.Nil Nil Poor appearance (4) Nil Nil Poor appearance (4) Nil Nil Dissatisfaction( No functional impact) Nil
Poke-Yoke
6 Improper staking in packing High cushion pressure 7 Clearance on the die & Punch
Prevention
Detection
90
Action Taken
Packing standard. Operating Procedure 4
PDI Inspection. Engg & QA Process to be stabilised 140 and to be validated & Jul-10 tools to be fine tuned 7 4 3 84
Preventive maintenance of First off / Patrol/Last Off Inspection the tool
No hole( Datum & Customer Fitment )missing
Punch Broken 8 Punch hight variation. Tool set up not done properly( Setting block ) Punch Broken 8 Punch hight variation. Tool set up not done properly( Setting block ) Improper Location 8 3 3 3
120
72
All hole Open
Hole Not Open

PTD
Customer End User
120
72
Next Opn No hole( Datum & Customer Fitment ) Hole position shift. Customer position shift. PTD End User Next Opn 40.Pierce & Separation No hole( missing Hole Missing Customer End User Next Opn No Double Piercing Double Piercing Customer End User Next Opn No Scrap Impression Scrap Impression Customer End User Next Opn Burr with in the Limit(Max=0.2mm) Burr Exceeds the limit Customer End User
A Critical Characterisitics
Preventive maintenance of the Tools.
First off / Patrol/Last Off Inspection.
Pin to be provided to locate hole in Next Engineering120 operation and Assembly July -2010 operation
72
Punch Broken 6 Punch hight variation. Tool set up not done properly( Setting block ) Part location/locator improper 4 3 3
90
First off / Patrol/Last Off Inspection Preventive maintenance of the Tools. 5 60 -
Improper Sie Insert Cleareance , Die Design 4 4 Preventive maintenance of the Tools.
PTD
Past Trouble Data
Significant Characterisitics
Recommended Action : If RPN 100 & Severity is 1 to 7 If RPN 80 & Severity is 8 & 9 If RPN > 10 & Severity is 10
Prepared By
RPN
Det(D)
Class

CES/FM/NS/036 4/4/2010 1 17/02/2011

Action Results
Detect
Occur
Sevr
Prevention
Detection
Action Taken
Prepared By
RPN
Det(D)
Class

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PROCESS FMEA CHECK SHEET

PFMEA NO.: CES/FM/NS/024-00

Doc No. : CES/ENG/F/25 Rev No 0

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)

Process Responsibility: Mfg-Press Shop Approval / Date : Key Date: 7/6/2011

Document Number Date (Org.) Revision No. Date (Rev.)

CES/FM/NS/036 4/4/2010 1 17/02/2011

Operation Number & Name

Chemical & Mechanical properties variation

Next Opn Customer End User Next Opn

Supplier process variation 2

Incoming Sample inspection

Supplier process variation 2

Supplier Inspection report

Incoming inspection(Test certificate)

Customer End User Next Opn

High cushion pressure Clearance on the die & Punch 5

Customer End User

Thinning( Up to 0.3T )minimum Thickness should be 0.8 mm.

High cushion pressure Clearance on the die & Punch 4

Operating procedure Preventive maintenance of the Tool

First off / Patrol/Last Off Inspection - Set up verification.

First off / Patrol/Last Off Inspection Set up Verification 5 80 -

First off / Patrol/Last Off Inspection 5 80 -

In draw operation air vent hole blocked 3

Preventive maintenance of First off / Patrol/Last Off the Tools Inspection 5 60 -

Operating Procedure Preventive maintenance Of the Tools

First off / Patrol/Last Off Inspection Set up Verification 5 75 -

First off / Patrol/Last Off Inspection

Engg & Die Maint

Operation / Process Function Requirements

Potential Failure Mode

Potential Effect(s) of Failure

Potential Cause(s) / Mechanism (s) of Failure

Current Process Control

Respons. And Target Date

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)

Process Responsibility: Mfg-Press Shop Approval / Date : Key Date: 7/6/2011

Document Number Date (Org.) Revision No. Date (Rev.)

CES/FM/NS/036 4/4/2010 1 17/02/2011

Operation Number & Name

Customer End User

Mis location Of the component

First off / Patrol/Last Off Inspection

Operating Procedure Operator training Packing standard. Operating Procedure

Preventive maintenance of First off / Patrol/Last Off Inspection the tool

No hole( Datum & Customer Fitment )missing

Preventive maintenance of First off / Patrol/Last Off the Tools Inspection.

Customer End User

Preventive maintenance of First off / Patrol/Last Off the Tools Inspection.

Preventive maintenance of the Tools.

First off / Patrol/Last Off Inspection.

Preventive maintenance of First off / Patrol/Last Off the Tools Inspection.

First off / Patrol/Last Off Inspection Preventive maintenance of the Tools. 5 60 -

Operation / Process Function Requirements

Potential Failure Mode

Potential Effect(s) of Failure

Potential Cause(s) / Mechanism (s) of Failure

Current Process Control

Respons. And Target Date

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)

Process Responsibility: Mfg-Press Shop Approval / Date : Key Date: 7/6/2011

Document Number Date (Org.) Revision No. Date (Rev.)