RPN Rating Scale Lower Upper 1 125

Action to be taken Move the X to Control Plan and record existing controls for X Take immediate action on X to reduce RPN to less than 125 Take X for Graphical and Statistical Analysis

Failure Mod

126

300

301 Note: Process or Product Name: Responsible:

1000

The above cut-off values are used as a thumbrule. Should you want to use different cut-offs, please change the above values

Process Function

Input

Characteristic of Input (KPIV / X)

Potential Failure Potential Effects Mode (How the X of Failure (Y or Minifails?) Y) Fails in Misture analysis test Product fails in maintaining the specific gravity Oil gets contaminated & affect the filling process Air entrapment and under fillung of bottles

S E V

Incoming tanker at BA's

Moisture analysis

Oil receipt
Incoming tanker at BA's

Foreign Material

Mixup with oil

Oil receipt
level of oil in the day tank

Oil receipt

Oil availability in Day tank

Service tank

Oil empty out

Oil receipt
Service tank

Service tank input People forgotten valve Valve not opened to open Service tank input People forgotten valve Valve not opened to open Service tank Air entrapment Float valve jamme Improper Improper weight tightment of setting center nut

Oil receipt Oil receipt

Service tank

Filling machine

Piston cylinder

ML Bed rod

Filling machine

Piston cylinder

ML Bed rod

Improper Improper weight tightment of setting center nut

Filling machine Filling machine

Piston cylinder Piston cylinder

ML Bed rod ML Bed rod

Improper weight setting Improper weight setting

Improper tightment of center nut Weight adjustment rod

Filling machine

Piston cylinder

ML Bed rod

Improper weight Weight setting adjustment rod

Filling machine

Piston cylinder

ML Bed rod

Improper weight Weight setting adjustment rod

Filling machine Filling machine

Piston cylinder Piston cylinder

Piston Piston

Deforming the shape Deforming the shape Sediments avaibility Sediments avaibility Weight variation Weight variation Sediments avaibility Sediments avaibility

Over loaded Over loaded Improper cleaning of the tank Improper cleaning of the tank Air entrapment Air entrapment Improper cleaning of the tank Improper cleaning of the tank
3

Filling machine

Piston cylinder

NRV

Filling machine Filling machine Filling machine

Piston cylinder Piston cylinder Piston cylinder

NRV Teflon washer Teflon washer

3 1

Filling machine

Front nozzle

NRV

Filling machine

Front nozzle

NRV

3 Filling machine

Front nozzle

Spring

Lose of elasticity

Life time exceeds

3 Filling machine Filling machine

Front nozzle Front nozzle Front nozzle

Oil dripping Oil dripping Oil dripping

Spring damaaged Life time exceeds Nozzle tip Improper damaged handling Nozzle tip damaged Improper handling

3 3

Filling machine

Filling machine

tare weight seting in the weighing Improper setting balance the nozzle Oil under filled

Tare weight issues

Filling machine

tare weight seting in the weighing Improper setting balance the nozzle Oil over filled
Electricity Voltage Fluxuation in the voltage

Tare weight issues

Damage the sensitive parts of the machine Defect or Machine damage Damage the sensitive parts of the machine Defect or Machine damage 9

Filling machine Operator Filling machine electricity Filling machine Filling machine Bottle Weighment Inspector Weigh Balance Skill Accuracy Voltage Fluxuation in the voltage Skillless operation Skill Skillless operation

3 9 9

Lower or Impropper result of Highercapacity than weight required Lower accuracy than required Impropper result of weight Tare weight will not correct & it affects the net weight of the bottle

Bottle Weighment

Weigh Balance

Capacity

Bottle Weighment

Weigh Balance

Zero setting not proper

Not covered properly

Bottle Weighment

Weigh Balance

Zero setting not proper

Not calibrated

Tare weight will not correct & it affects the net weight of the bottle

Bottle Weighment

Tare weight

Empty bottle weight

Bottle above / Will affect the below specifications weight in FG stage

Bottle Weighment

Bottle weight Identifications

Actual bottle weight identifications

Wrong weight identifications

Improper net weight calculations due to wrong tare weight Wrongly recording / Not readable

Bottle Weighment

Bottle weight Identifications

Filled bottle weight

Note the filled weight

Bottle Weighment

Bottle weight Identifications

Calculation of net weight

Wrong calculation

Wrong recording of the net weight

Process / Product Failure Modes and Effects Analysis (FMEA)

Prepared by: FMEA Date (Orig) ______________ (Rev) _____________ Potential Cause(s)/ Mechanism(s) of Failure (Sub X's) Water mixup on the oil Improper cleaning of the tank / Not closed the tanker properly Minimum stock level not maintained O C C Current Process Controls Incoming oil inspection of moisture analysis test -SOP Incoming oil inspection for foreign Material SOP D E T R P N

Page ____ of ____

Recommended Action(s)

27

no control

729

auto feedback loop for low and high pump start up and stoppage to be implimented

Unskilled manpower

Trained person to take the ownership

Checklist for startup of the filling

27

Filter bag not tied properly Thread damaged in the nut

Transparent Sheet provided

MSL is not maintained in PAC

27 Critical spares list maintained

486

PAC

18

Bush worn out

skill building needs to be performed to build multiple authority for weight setting

Critical spares list maintained Operator trained before put in Job authority and mistake proffing for SKU wise setting to be done

162

Unskilled manpower Thread Worn out Frequent adjustment of the rod Adjustment done without loosing the center nut Improper handling while adjusting the weight Cylinder sleeve jamme Non adhering the cleaning schedule Filter cloth damaged Improper fitting Damaged in the washer Non adhering the cleaning schedule Filter cloth damaged
6

PAC Operator trained before put in Job

18

27

Operator trained before put in Job

18

Operator trained before put in Job

27

PAC Operator trained before put in Job

27

PAC Operator trained before put in Job Maintaining the spares Operator trained before put in Job

3 3

1 3

9 9

PAC

1 frequency to be foud out using the mechanical engg hand book, after spring type and specifications

Not determining the life time

Frequency of changing system to be implemented

162

Not determining the life time Unskilled persons Frequent chnge over 10 botle are checked for averaging the tare waight to be adjusted in the weighing machine 10 botle are checked for averaging the tare waight to be adjusted in the weighing machine
Electrical consumption variation between machines Inadequate training or less experience 3 6

Frequency of changing system to be implemented Operator trained before put in Job Weight setting design to be modified

162

frequency to be foud out using the mechanical engg hand book, after spring type and specifications

3 9

27 162 match making for SKU change has to be put in place

every lot change this activity I performed

108

every lot change this activity I performed

108

Stabiliser available to reduce the electrical noise Operator trained before put in Job

81

81

3 Inadequate training Less awareness in selection of wighbalance Less awareness in selection of wighbalance Disturbances by air / External forces / Unlevelled machine 3 3 Operator trained before put in Job Technical guidance from ML given Technical guidance from ML given Weighing balnce covered & calibrated daily

1 3 3

9 81 81

81

72

Disturbances by air / External forces / Unlevelled machine

Weighing balnce covered & calibrated daily

108

Change in the weight during the blowing process

On - line checking at blowing locations & weight checking at incoming PM stage

64

skill building not done

no control

486

Training provided to the operator with scheduled check audits Training provided to the operator with scheduled check audits Training provided to the operator with scheduled check audits

skill building not done

no control

486

skill building not done

no control

486

Action Results Responsibility Completion Date Actions Taken

S E V S E V

O C C O C C

Sabar and Ganesh

10.11.11

Sabar and Ganesh

15.11.11

Sabar and Ganesh

15.11.11

ganesh

15.11.11

ganesh

15.11.11

Sabar and Ganesh

20.11.11

ganesh

15.11.11

ganesh

15.11.11

ganesh

15.11.11

D E T D E T

R P N R P N

Improve the Filling Machine Setting

Sl No X
level of oil in the day tank

Description of the X
Oil empty out

1 pistion cylinder setting of ML Bed rod thread damaged

Improper weight setting

Improper Fill weight setting

Improper weight setting

4 5 6 7 8 9 10

Cylinder size Nozzle Spring Oil dripping from nozzle Oil dripping from nozzle
Bottle weight checking Filled bottle weight Calculation of net weight

Higher cylinder size leads to overfill Loss of elasticity Spring damaaged Nozzle tip damaged
Wrong weight identifications Weight recording structure Wrong calculation

Setting
Actions to be performed
auto feedback loop for low and high pump start up and stoppage to be implemented

Critical spares list maintained

Develop SOP for the Fill weight setting. Use the New Jig & Fixture (Provided to SME) for setting fill weight accurately

Make the Fill volume matches the Cylinder volume

Use of spring steel for nozzle return spring Use of spring steel for nozzle return spring Maintain necessary spare nozzle Training provided to the operator with scheduled check audits Training provided to the operator with scheduled check audits Training provided to the operator with scheduled check audits

Process Set zero on the weighing m/c Set zero on the weighing m/c

Input weighing m/c

Characteristic of calibrated m/c

Potential Failure zero setting not proper hence change in bias level setting not proper hence change in bias

weighing m/c

Leveled

Potential Effects tare weight will not be correct & same will change net weighjt filled tare weight will not be correct & same will change net weighjt filled

Weight the empty bottles Write the tare weight of bottle on the bottles using temporary marker Weight the Filled bottles Writing of Net Weights on Weight Page

Tare weight

Empty bottle weight

Bottle below/above will effect the weight in specification the FG stage

bottle weight identification

improper net weight actual bottle weight wrong identification/ calculation due to identification not readable wrong tare weight wrong recording/ note filled weight not readable Calculation of Net wrong calculation weight improper net weight calculation due to wrong tare weight wrong typing of the fig Higher time to set machine hence keeping weight on the higher side higher/ lower weight filled. higher/ lower weight filled.

Operator Operator

MAN Improper setting of m/c MACHINE MACHINE Nozzle Dripping Nozzle Dripping

Improper training

wrong adjustment practice weight variation due to extra oil dripping from weight variation due to extra oil dripping from

Nozzle pipe end damage Hose connection loose near NRV

Potential Effects S E V Potential Cause(s)/O C C Current D E T are weight will not be disturbance by air/ correct & same will weigh balance covered 9 external forces/ 3 3 change net weighjt & calibrated every day unlevelled machine disturbance external forces/ unlevelled machine changes in the weight during blowing proces weigh balance covered & calibrated every day online check at blowing location & weight check at incoming stage at PM reciept

R P N 81

are weight will not be correct & same will change net weighjt

54

will effect the weight in he FG stage

567

mproper net weight calculation due to wrong tare weight

improper writing

trainign provided to the operator

105

mproper net weight calculation due to wrong tare weight

7 7

improper writing improper keying of the fig. wrong practice of weigt setting & change in the machine weight adjustment block setting. crack in the nozzle end Loosening of the hose due to continous movement

3 3

trainign provided to the operator trainign provided to the operator

5 5

105

wrong typing of the fig

105

Higher time to set machine hence keeping weight on the

training of the operator

729

higher/ lower weight

6 6

3 2

higher/ lower weight

checked in case of any dripping oberved during filling checked in case of any dripping oberved during filling

5 5

90 60