Failure Mode and Effects Analysis

PART NAME: DRIVE END SHIELD

PART NUMBER: 2 005 835 703

No. Component or Process Function Failure Mode Failure Effect S C Failure Cause O

due to defect at ingot

RECIPT & INSPECTION CHEMICAL COMPOSITION CHANGE IN PROPERTIES AND
10.0 OF AL.ALLOY/ STORAGE RAW - MATERIAL 8 manufacturer & improper 3
NOT AS PER SPEC DEFECTIVE CASTINGS incoming control.

SET TEMP IS LOW IN

20.0 8 * 3
FURNACE
METAL TEMPERATURE LOW COLD SHUT / FLOW MARK
640' C
20.1 8 COIL WORNOUT IN FURNACE 3

MOLTEN METAL SET TEMP IS HIGH IN

20.2 8 3
FURNACE

METAL TEMP HIGHER THAN SOLDERING & GAS POROSITY IMPROPER SETTING OF
20.3 685'C 8 * 2
METAL MELTING & CUTOFF TEMP
DEGASSING

20.4 8 THERMOCOUPLE CABLE CUT 3

CHANGE IN PROPERTIES AND

CHEMICAL COMPOSITION LINISHING NOT DONE
20.5 MOLTEN METAL DEFECTIVE CASTINGS. AND 8 3
VARIATION. (SPECTRO) PROPERLY
CUSTOMER COMPLAINT.

20.6 MOLTEN METAL INCLUSION (K-MOULD) HARD SPOT IN CASTING. 8 insufficient fluxing. 3

Page 1 of 24
 METAL MELTING &
DEGASSING

Failure Mode and Effects Analysis

PART NAME: DRIVE END SHIELD

PART NUMBER: 2 005 835 703

No. Component or Process Function Failure Mode Failure Effect S C Failure Cause O

DISSOLVED GASSES
20.7 MOLTEN METAL BLOW HOLES IN CASTING. 8 insufficient degassing 3
(POROSITY)
BA =
Critical
Major METAL FLASHING OUT FROM CHANGES IN LOCK NUT
BA30.0= LOCKING FORCE - LESS DIE. 8 READINGS 3
Critical
Major
BA = GAS POROSITY IN THICK CHANGES IN LOCK NUT
30.1 LOCKING FORCE - MORE 8 3
Critical
Major SECTIONS. READINGS

30.2 1ST PHASE - LOW FLOW DEFECTS OBSERVED. 8 * SETTING PROBLEM 3

DIE LOADING AND MACHINE
SETTING FLOW MARKS OBSERVED DUE
30.3 1ST PHASE - HIGH TO TURBULANCE AND 8 SETTING PROBLEM 3
DIE FLASHING.
FLOW DEFECTS & BLOW
30.4 2ND PHASE - LESS HOLES AWAY FROM THE 8 SETTING PROBLEM 3
GATE.

DIE FLASHING & CORE, PINS

30.5 2ND PHASE - HIGH 8 SETTING PROBLEM 3
SOLDERING.

30.6 3RD PHASE - LOW SHIRNKAGE/ POROSITY 8 SETTING PROBLEM 3

CA
B ==
Critical
Major
Minor
30.7 DIE FLASHING & SOLDER 8 SETTING PROBLEM 3
3RD PHASE - HIGH MARK ON GATE AREA
CA
B ==
Critical
Major
Minor

Page 2 of 24
 Failure Mode and Effects Analysis

PART NAME: DRIVE END SHIELD

PART NUMBER: 2 005 835 703

No. Component or Process Function Failure Mode Failure Effect S C Failure Cause O
CA
B ==
Critical
Major
Minor
CA
B == COMPONENT GET
Minor
Critical
Major
B
CA30.8== DISTORSION AND SHIRNKAGE IMPROPER CYCLE TIME
CYCLE TIME - LESS 8 3
Critical
Major
Minor DUE TO DIFFERENCE IN WALL SETTING
THICKNESS
BA =
Critical
Major
B
CA ==
Critical
Major
Minor
BA = CRACK DURING EJECTION IMPROPER CYCLE TIME
30.9
Critical
Major CYCLE TIME - HIGH 8 3
AND FLOW DEFECTS SETTING
BA
C ==
Critical
Major
Minor HEAT EXCHANGER NOT
30.10 8 3
BA = WORKING PROPERLY
PUMP PRESSURE LOW,OIL
Critical
Major
B
CA == OIL TEMP ABOVE 55'C
DIE LOADING AND LEAKAGE & O'RING CUT
Critical
Major
Minor
BA30.11= SETTING MACHINE 8 OIL LEVEL LOW 3
Critical
Major
BA
C ==
Critical
Major
Minor WATER MIX UP WIYH
30.12 OIL TEMP BELOW 45'C CYCLE TIME WILL BE MORE 8 HYDRUALIC OIL DUE HEAT 3
EXCHANGER HOSE LEAKAGE.
CA
B ==
Critical
Major
Minor
30.13 8 N2 VALVE LEAKAGE 3
CA
B ==
Critical
Major
Minor
ACUMULATOR 'O'RING
30.14 8 * 3
DAMAGE
N2 PRESSURE LESS THAN BLOW HOLES/COLD
120 Kg/cm2 SHUT,NON-FILLING.
30.15 8 PISTON O'RING DAMAGE 2

Page 3 of 24
 SETTING

Failure Mode and Effects Analysis

PART NAME: DRIVE END SHIELD

PART NUMBER: 2 005 835 703
N2 PRESSURE LESS THAN BLOW HOLES/COLD
120 Kg/cm2 SHUT,NON-FILLING.
No. Component or Process Function Failure Mode Failure Effect S C Failure Cause O

30.16 8 N2 GAUGE NOT WORKING 2

* defective casting produce. *

CA40.0==
B Customer would be dis- 8 LADDLE SIZE LESS 3
Critical
Major
Minor satisfied. * BLOW HOLES,
POURING QTY- LESS NON-FILLING,CASTING
METAL POURING STRUCK & LOW CASTING
STRENGTH. OPERATOR SKILL DURING
40.1 POURING INTO THE SHOT 8 4
SLEEVE POURING

* defective casting produce. *

Customer would be dis-
40.2 POURING QTY-MORE 8 LADDLE SIZE MORE 3
satisfied. *Die flash, runner
struck.

SPRUE BUSH DIA NOT AS PER PLUNGER STRUCK/ CASTING DIMENTION VARIATION/
50.0 8 3
SPEC NOT OK BUSH WEAR OUT

METAL COMES OUT FROM

50.1 DIE FLASHING 8 INSERT FACE NOT MATCHING 3
MOULD

WRONG POSITION OF
50.2 UNEVEN EJECTION CASTING BEND 8 2
EJECTION ROD
DIE CASTING MOULD

Page 4 of 24
 Failure Mode and Effects Analysis

PART NAME: DRIVE END SHIELD

PART NUMBER: 2 005 835 703

No. Component or Process Function Failure Mode Failure Effect S C Failure Cause O
DIE CASTING MOULD

50.3 EJECTOR & CORE PINS CASTING NOT AS PER SPEC 8 * WEAR OUT & THERMAL 3
BROKEN FATIGUE

50.4 DIE TEMPERATURE - LOW CASTING GET STRUCT , FLOW 8 DYCOTE SPRAYING - MORE 3
DEFECTS AND SOLDERING

BUBBLES , SHIRNKAGE AND

50.5 DIE TEMPERATURE - HIGH 8 DYCOTE SPRAYING - LESS 3
WELD ON CASTINGS

50.6 DIE CASTING FREE FROM 8 LOW INJECTION PRESSURE 3

VISUAL DEFECTS
*

50.7 8 SETTING PROBLEM 3

50.8 8 DIE FLASHING 3

NON - FILLING/ FLOW MARK DEFFECTIVE CASTING

50.9 8 LOW METAL TEMPRATURE 4

50.10 8 METAL QTY LESS 3

Page 5 of 24
 Failure Mode and Effects Analysis

NON - FILLING/ FLOW MARK DEFFECTIVE CASTING

PART NAME: DRIVE END SHIELD
PART NUMBER: 2 005 835 703

No. Component or Process Function Failure Mode Failure Effect S C Failure Cause O

50.11 8 PLUNGER TIP FLASHING 4

50.12 8 HIGH METAL TEMP 3

CRACK & BROKEN & BLISTER. DEFFECTIVE CASTING

50.13 8 HIGH DIE TEMP 3

50.14 8 LESS SOLDIFICATION TIME 3

50.15 8 DYCOTE SPRAYING 3

SOLDERING ,CASTING CASTING REJECTION

CATCHING & WELD MARK
50.16 8 HIGH DIE TEMP 3

50.17 DIE CASTING FREE FROM AFTER SPIGOT DIA FACE NON * CUSTOMER WOULD BE 8 * MACHINING STOCK IS LESS. 3
MACHINING NC. CLEARANCE. DISSATISFIED.

Page 6 of 24
 Failure Mode and Effects Analysis

PART NAME: DRIVE END SHIELD

PART NUMBER: 2 005 835 703

No. Component or Process Function Failure Mode Failure Effect S C Failure Cause O

FREE FROM
MACHINING * CUSTOMER WOULD BE
50.18 DIE CASTING SPIGOT dia BLOW HOLE 8 * INSUFFICIENT GATE DEPTH. 3
BLOW HOLE DISSATISFIED.
DEFECTS

50.19 8 * INSUFFICIENT OVER FLOW 3

VOLUME.

50.2 8 * INSUFFICIENT OVER FLOW 3

VENTING.

50.21 8 * INSUFFICIENT GATE LAND. 3

* INSUFFICIENT GATE WIDTH.

50.22 8 3

* INSUFFICIENT RUNNER
50.23 8 3
DEPTH.

50.24 8 * EXCESS MACHINING STOCK. 3

Page 7 of 24
 Failure Mode and Effects Analysis

PART NAME: DRIVE END SHIELD

PART NUMBER: 2 005 835 703

No. Component or Process Function Failure Mode Failure Effect S C Failure Cause O

FREE FROM AFTER MOUNTING HOLE NC. * CUSTOMER WOULD BE

50.25 DIE CASTING 8 * MACHINING STOCK IS LESS. 3
MACHINING NC. DISSATISFIED.

FREE FROM
MACHINING MOUNTING HOLE BLOWHOLE *DISSATISFIED.
CUSTOMER WOULD BE
50.26 DIE CASTING 8 * INSUFFICIENT GATE DEPTH. 3
BLOW HOLE
DEFECTS

* INSUFFICIENT OVER FLOW

50.27 8 3
VOLUME.

* INSUFFICIENT OVER FLOW

50.28 8 3
VENTING.

* INSUFFICIENT GATE WIDTH.

50.29 8 3

* INSUFFICIENT RUNNER
50.3 8 3
DEPTH.

50.31 8 * EXCESS MACHINING STOCK. 3

Page 8 of 24
 Failure Mode and Effects Analysis

PART NAME: DRIVE END SHIELD

PART NUMBER: 2 005 835 703

No. Component or Process Function Failure Mode Failure Effect S C Failure Cause O

FREE FROM AFTER YOKE DIA NC. * CUSTOMER WOULD BE

50.32 DIE CASTING 8 * MACHINING STOCK IS LESS. 3
MACHINING NC. DISSATISFIED.

FREE FROM
MACHINING * CUSTOMER WOULD BE
50.33 DIE CASTING YOKE DIA BLOWHOLE 8 * INSUFFICIENT GATE DEPTH. 3
BLOW HOLE DISSATISFIED.
DEFECTS

* INSUFFICIENT OVER FLOW

50.34 8 3
VOLUME.

* INSUFFICIENT OVER FLOW

50.35 8 3
VENTING.

* INSUFFICIENT GATE WIDTH.

50.36 8 3

* INSUFFICIENT RUNNER
50.37 8 3
DEPTH.

50.38 8 * EXCESS MACHINING STOCK. 3

Page 9 of 24
 Failure Mode and Effects Analysis

PART NAME: DRIVE END SHIELD

PART NUMBER: 2 005 835 703

No. Component or Process Function Failure Mode Failure Effect S C Failure Cause O

IMPROPER FETTLING &

60.0 EXCESS FETTLING rejection / defective casting. 8 * 3
CASTING HANDLING

60.1 DIMENSION UNDER SIZE rework 8 LESS STOCK REMOVED 3

60.2 REMOVE THE DIMENSION OVER SIZE rejection 8 MORE STOCK REMOVED 3
BURRS/ FLASHS
FETTLING INTO MANUAL
PROCESS
60.3 8 NEW FETTLER NOT TRAINED 4
FLASH NOT REMOVED customer complaint.

60.4 8 IMPROPER FETTLING TOOLS 3

FETTLING NOT DONE

60.5 customer complaint. 8 PARTS MIX UP 2
PROPERLY

STAINLESS STEEL BALL SIZE CORRECT SIZE BALL NOT

70.0 casting rejection. 8 3
LESS THAN 0.5 AVAILABLE

STAINLESS STEEL BALL SIZE customer complaint./ dent CORRECT SIZE BALL NOT
70.1 8 3
MORE THAN 0.5 mark. AVAILABLE

shotblasting coverage is less Re-shotblasting / casting

70.2 8 loading quantity is high/low 2
or more. rejection.

SURFACE FINISH /
SHOT BLASTING TO REMOVE THIN
FLASH
Page 10 of 24
 Failure Mode and Effects Analysis

PART NAME: DRIVE END SHIELD

PART NUMBER: 2 005 835 703

No. Component or Process Function Failure Mode Failure Effect S C Failure Cause O

SURFACE FINISH /
SHOT BLASTING TO REMOVE THIN *casting rejection, customer
70.3 FLASH 8 OPERATOR CARELESS 2
complaint.
cycle time is more.
*casting rejection, customer
70.4 8 TIMER SWITCH PROBLEM 2
complaint.

*casting rejection, customer

70.5 8 OPERATOR CARELESS 2
complaint.
cycle time is less
*casting rejection, customer
70.6 8 TIMER SWITCH PROBLEM 2
complaint.

1) Improper Inspection
80.0 final Inspection check the casting visual defects, dimensional CASTING REJECTION/ 8 2) Improper measuring 2
quality deviations. customer complaint Instruments

* packing person not

90.0 *customer complaint. 8 3
awareness give.
*Less or more qty packed.

90.1 PACKING casting Packed *customer complaint. 8 *insufficient training. 3

*customer complaint.
90.2 *improper packing. 8 *insufficient training. 2
*damage during transport.

Page 11 of 24
 Document No.: ASW / F / 85
e Mode and Effects Analysis
FMEA Rev.No./Date: 01/10.6.2019
AME: DRIVE END SHIELD FMEA Original Date : 27.4.2019
UMBER: 2 005 835 703 Page :

Actions
Failure Prevention D Failure Detection RPN S O D RPN
R: / I:

COLOUR IDENTIFICATION CHECKING CHEMICAL

4 96
AND TEST REPORT COMPOSITION WITH OUR LAB.

SET TEMP AS PER TEMP RECORDED IN process

MOP/CHECK THE TEMP 4 parameter record FROM TEMP 96
CONTROLLER. INDICATOR.

TEMP RECORDED IN process

PREVENTIVE MAINTENANCE 4 parameter record FOR EVERY 96
HOUR FROM TEMP INDICATOR.

SET TEMP AS PER TEMP RECORDED IN process

MOP/CHECK THE TEMP 4 parameter record FROM TEMP 96
CONTROLLER. INDICATOR

TEMP RECORDED IN process

INSTRUCTION / TRAINING 5 parameter record FROM TEMP 80
INDICATOR

TEMP RECORDED IN process

PREVENTIVE MAINTENANCE 4 parameter record FROM TEMP 96
INDICATOR

LINISHING SHOULD BE DONE CHECK WITH SPECTROMETER

3 72
PROPERLY. TEST.

Monitor of fluxing process

AND SHOULD BE DONE 3 CHECK WITH K-MOULD TEST. 72
PROPERLY.

Page 12 of 24
 Document No.: ASW / F / 85
e Mode and Effects Analysis
FMEA Rev.No./Date: 01/10.6.2019
AME: DRIVE END SHIELD FMEA Original Date : 27.4.2019
UMBER: 2 005 835 703 Page :

Actions
Failure Prevention D Failure Detection RPN S O D RPN
R: / I:

Monitor of degassing process

AND SHOULD BE DONE 3 CHECK WITH POROSITY TEST. 72
PROPERLY.

REFER MACHINE OPERATING RECOD IN PROD REPORT

3 72
PARAMETER (EVERY SHIFT)

REFER MACHINE OPERATING RECOD IN PROD REPORT

3 72
PARAMETER (EVERY SHIFT)

SET AS PER MACHINE PROCESS PARAMETER RECORD

4 96
OPERATING PARAMETER (EVERY SHIFT)

SET AS PER MACHINE RECORD IN PROD REPORT

4 96
OPERATING PARAMETER (EVERY SHIFT)

SET AS PER MACHINE PROCESS PARAMETER RECORD

4 96
OPERATING PARAMETER (EVERY SHIFT)

SET AS PER MACHINE RECORD IN PROD REPORT

4 96
OPERATING PARAMETER (EVERY SHIFT)

SET AS PER MACHINE PROCESS PARAMETER RECORD

4 96
OPERATING PARAMETER (EVERY SHIFT)

SET AS PER MACHINE 4 PROCESS PARAMETER RECORD 96

OPERATING PARAMETER (EVERY SHIFT)

Page 13 of 24
 Document No.: ASW / F / 85
e Mode and Effects Analysis
FMEA Rev.No./Date: 01/10.6.2019
AME: DRIVE END SHIELD FMEA Original Date : 27.4.2019
UMBER: 2 005 835 703 Page :

Actions
Failure Prevention D Failure Detection RPN S O D RPN
R: / I:

SET AS PER MACHINE PROCESS PARAMETER RECORD

4 96
OPERATING PARAMETER (EVERY SHIFT)

SET AS PER MACHINE PROCESS PARAMETER RECORD

4 96
OPERATING PARAMETER (EVERY SHIFT)

INSTRUCTION / PREVENTIVE 5 MAINTENANCE REGISTER RECORD 120

MAINTENANCE PLAN

INSTRUCTION / PREVENTIVE 5 MAINTENANCE REGISTER RECORD 120

MAINTENANCE PLAN

INSTRUCTION / PREVENTIVE 5 MAINTENANCE REGISTER RECORD 120

MAINTENANCE PLAN

INSTRUCTION / PREVENTIVE PROCESS PARAMETER RECORD

4 96
MAINTENANCE PLAN (EVERY SHIFT)

INSTRUCTION / PREVENTIVE 5 MAINTENANCE REGISTER RECORD 120

MAINTENANCE PLAN

INSTRUCTION / PREVENTIVE 5 MAINTENANCE REGISTER RECORD 80

MAINTENANCE PLAN

Page 14 of 24
 Document No.: ASW / F / 85
e Mode and Effects Analysis
FMEA Rev.No./Date: 01/10.6.2019
AME: DRIVE END SHIELD FMEA Original Date : 27.4.2019
UMBER: 2 005 835 703 Page :

Actions
Failure Prevention D Failure Detection RPN S O D RPN
R: / I:

CALIBIRATION PLAN/ DAILY PROCESS PARAMETER RECORD

MONITOR 5 80
(EVERY SHIFT)

* asper machine operating

parameter, laddle size to be 4 PROCESS PARAMETER RECORD 96
modify, according to failure
cause.

OPERATOR TRAINING 3 TRAINING PLAN 96

* asper machine operating

parameter, laddle size to be 4 PROCESS PARAMETER RECORD 96
modify, according to failure
cause.

CHECK SPRUE BUSH DIA &

SELECT PLUNGER BORE GAUGE & RECORD IN DIE
4 96
SIZE/CHANGE THE SPRUE SERVICE
BUSH

AFTER UNLOADING THE DIE CHECK LAST SHOT & RECORD IN

DURING SERVICE BLUE 3 72
DIE SERVICE
MATCHING WILL BE DONE

CHECK EJECTION ROD

LENGTH DURING SERVICE, 7 VISUAL 112
THE EJECTION ROD LENGTH
SHOULD BE EVEN

Page 15 of 24
 Document No.: ASW / F / 85
e Mode and Effects Analysis
FMEA Rev.No./Date: 01/10.6.2019
AME: DRIVE END SHIELD FMEA Original Date : 27.4.2019
UMBER: 2 005 835 703 Page :

Actions
Failure Prevention D Failure Detection RPN S O D RPN
R: / I:

DIE MAINTENANCE CHECKING

THE CORE PINS WHILE DIE 4 VISUAL / PATROL INSPECTION 96
SERVICING.

CHECK DIE TEMP &

INSTUCTION / OPERATOR 4 DIE TEMP INDICATOR/RECORD IN 96
TRAINING PROD REPORT

CHECK DIE TEMP & DIE TEMP INDICATOR/RECORD IN

INSTUCTION / OPERATOR 4 96
TRAINING PROD REPORT

PROCESS MONITORING 4 INPROCESS INSPECTION 96

PROCESS MONITORING/ PROCESS PARAMETER RECORD

ADJUSTING THE SETTING TO 4 96
(EVERY SHIFT)
CONTROL THE REJECTION.

AFTER UNLOADING THE DIE CHECK LAST SHOT & RECORD IN

DURING SERVICE BLUE 3 DIE HISTORY CARD. 72
MATCHING WILL BE DONE.

PROCESS MONITORING 3 INPROCESS INSPECTION 96

PROCESS MONITORING/
MAINTAIN THE METAL QTY 3 FIRST OFF INSPECTION 72
THROUGH PROPER LADDLE.

Page 16 of 24
 Document No.: ASW / F / 85
e Mode and Effects Analysis
FMEA Rev.No./Date: 01/10.6.2019
AME: DRIVE END SHIELD FMEA Original Date : 27.4.2019
UMBER: 2 005 835 703 Page :

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PLUNGER SIZE MONITORING 3 PRODUCTION REPORT 96

PROCESS MONITORING/
REDUCE THE FURNACE TEMP 4 INPROCESS INSPECTION 96
/ CHECK THE TEMP
CONTROLLER

PROCESS MONITORING/DIE
COOLING SHOULD BE GIVE / 4 INPROCESS INSPECTION 96
DYCOTE SPRAYING TO BE
CONTROL

PROCESS MONITORING 4 INPROCESS INSPECTION 96

PROCESS MONITORING 4 INPROCESS INSPECTION 96

PROCESS MONITORING/ DIE

COOLING SHOULD BE GIVE / 4 INPROCESS INSPECTION 96
DYCOTE SPRAYING TO BE
CONTROL

* DIE TO BE MODIFIED * DURING STOCK ANALYSIS,

ACCORDING TO FALIURE 4 BASED ON THE STOCK, THE 96
CAUSE. FAILURE CAUSE TO BE DETECT.

Page 17 of 24
 Document No.: ASW / F / 85
e Mode and Effects Analysis
FMEA Rev.No./Date: 01/10.6.2019
AME: DRIVE END SHIELD FMEA Original Date : 27.4.2019
UMBER: 2 005 835 703 Page :

Actions
Failure Prevention D Failure Detection RPN S O D RPN
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* DURING FLOW ANALYSIS

* DIE TO BE MODIFIED BASED ON THE GATE
ACCORDING TO FALIURE 4 96
CALCULATION THE FAILURE
CAUSE. CAUSE TO BE DETECT.

* DIE TO BE MODIFIED * DURING FLOW ANALYSIS

ACCORDING TO FALIURE 5 BASED ON THE GATE 120
CALCULATION THE FAILURE
CAUSE. CAUSE TO BE DETECT.

* DIE TO BE MODIFIED * DURING FLOW ANALYSIS

ACCORDING TO FALIURE 5 BASED ON THE GATE 120
CALCULATION THE FAILURE
CAUSE. CAUSE TO BE DETECT.

* DURING FLOW ANALYSIS

* DIE TO BE MODIFIED BASED ON THE GATE
ACCORDING TO FALIURE 4 96
CALCULATION THE FAILURE
CAUSE. CAUSE TO BE DETECT.

* DURING FLOW ANALYSIS

* DIE TO BE MODIFIED BASED ON THE GATE
ACCORDING TO FALIURE 4 96
CALCULATION THE FAILURE
CAUSE. CAUSE TO BE DETECT.

* DURING FLOW ANALYSIS

* DIE TO BE MODIFIED BASED ON THE RUNNER
ACCORDING TO FALIURE 4 96
CALCULATION THE FAILURE
CAUSE CAUSE TO BE DETECT.

* DIE TO BE MODIFIED * EXCESS MACHINING STOCK TO

ACCORDING TO FALIURE 4 BE AVIOD, TO REDUCE THE 96
CAUSE BLOWHOLE IN SPIGOT OD.

Page 18 of 24
 Document No.: ASW / F / 85
e Mode and Effects Analysis
FMEA Rev.No./Date: 01/10.6.2019
AME: DRIVE END SHIELD FMEA Original Date : 27.4.2019
UMBER: 2 005 835 703 Page :

Actions
Failure Prevention D Failure Detection RPN S O D RPN
R: / I:

* DIE TO BE MODIFIED * DURING STOCK ANALYSIS,

ACCORDING TO FALIURE 4 BASED ON THE STOCK, THE 96
CAUSE. FAILURE CAUSE TO BE DETECT.

* DURING FLOW ANALYSIS

* DIE TO BE MODIFIED BASED ON THE GATE
ACCORDING TO FALIURE 4 96
CALCULATION THE FAILURE
CAUSE. CAUSE TO BE DETECT.

* DURING FLOW ANALYSIS

* DIE TO BE MODIFIED BASED ON THE GATE
ACCORDING TO FALIURE 4 96
CALCULATION THE FAILURE
CAUSE. CAUSE TO BE DETECT.

* DURING FLOW ANALYSIS

* DIE TO BE MODIFIED BASED ON THE GATE
ACCORDING TO FALIURE 5 120
CALCULATION THE FAILURE
CAUSE. CAUSE TO BE DETECT.

* DURING FLOW ANALYSIS

* DIE TO BE MODIFIED BASED ON THE GATE
ACCORDING TO FALIURE 4 96
CALCULATION THE FAILURE
CAUSE. CAUSE TO BE DETECT.

* DURING FLOW ANALYSIS

* DIE TO BE MODIFIED BASED ON THE RUNNER
ACCORDING TO FALIURE 4 96
CALCULATION THE FAILURE
CAUSE. CAUSE TO BE DETECT.

* TO CONTROL THE FAILURE

* DIE TO BE MODIFIED CAUSE AS BLOWHOLE TO BE
ACCORDING TO FALIURE 4 96
DETECT BY REDUCING
CAUSE. MACHINING PROCESS.

Page 19 of 24
 Document No.: ASW / F / 85
e Mode and Effects Analysis
FMEA Rev.No./Date: 01/10.6.2019
AME: DRIVE END SHIELD FMEA Original Date : 27.4.2019
UMBER: 2 005 835 703 Page :

Actions
Failure Prevention D Failure Detection RPN S O D RPN
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* DIE TO BE MODIFIED * DURING STOCK ANALYSIS,

ACCORDING TO FALIURE 4 BASED ON THE STOCK, THE 96
CAUSE. FAILURE CAUSE TO BE DETECT.

* DURING FLOW ANALYSIS

* DIE TO BE MODIFIED BASED ON THE GATE
ACCORDING TO FALIURE 4 96
CALCULATION THE FAILURE
CAUSE. CAUSE TO BE DETECT.

* DURING FLOW ANALYSIS

* DIE TO BE MODIFIED BASED ON THE GATE
ACCORDING TO FALIURE 4 96
CALCULATION THE FAILURE
CAUSE. CAUSE TO BE DETECT.

* DURING FLOW ANALYSIS

* DIE TO BE MODIFIED BASED ON THE GATE
ACCORDING TO FALIURE 4 96
CALCULATION THE FAILURE
CAUSE. CAUSE TO BE DETECT.

* DURING FLOW ANALYSIS

* DIE TO BE MODIFIED BASED ON THE GATE
ACCORDING TO FALIURE 4 96
CALCULATION THE FAILURE
CAUSE. CAUSE TO BE DETECT.

* DURING FLOW ANALYSIS

* DIE TO BE MODIFIED BASED ON THE RUNNER
ACCORDING TO FALIURE 4 96
CALCULATION THE FAILURE
CAUSE. CAUSE TO BE DETECT.

* TO CONTROL THE FAILURE

* DIE TO BE MODIFIED CAUSE AS BLOWHOLE TO BE
ACCORDING TO FALIURE 4 96
CAUSE. DETECT BY REDUCING
MACHINING PROCESS.

Page 20 of 24
 Document No.: ASW / F / 85
e Mode and Effects Analysis
FMEA Rev.No./Date: 01/10.6.2019
AME: DRIVE END SHIELD FMEA Original Date : 27.4.2019
UMBER: 2 005 835 703 Page :

Actions
Failure Prevention D Failure Detection RPN S O D RPN
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WORK INSTRUCTION/
PROPER TOOL SHOULD BE 3 FETTLING INSPECTION REPORT 72
USED / MARKING THE
CRITICAL AREA .

INSPECT EVERY 2 HRS ONCE 3 DIAL CALIPER / PLUG GAUGE 72

INSPECT EVERY 2 HRS ONCE 3 DIAL CALIPER / PLUG GAUGE 72

FOLLOW THE WORK

INSTRUCTION / LIMIT 3 LIMIT SAMPLE 96
SAMPLE

WORK INSTRUCTION 4 LIMIT SAMPLE 96

USE YELLOW CABIN FOR 100% VISUAL INSPECTION TO BE

7 112
CASTING REWORK DONE BEFORE DESPATCH

MINIMUM STOCK TO BE CHECK ALL THE CRITICAL STOCK

MAINTAINED FOR ALL 4 96
ONCE IN A WEEK
CRITICAL SPARES

MINIMUM STOCK TO BE CHECK ALL THE CRITICAL STOCK

MAINTAINED FOR ALL 4 96
CRITICAL SPARES ONCE IN A WEEK

TRAINING & LOADING QTY *sample to be approved.

INDENTIFICATION TO BE 7 112
*100% visual inspection.
DONE

Page 21 of 24
 Document No.: ASW / F / 85
e Mode and Effects Analysis
FMEA Rev.No./Date: 01/10.6.2019
AME: DRIVE END SHIELD FMEA Original Date : 27.4.2019
UMBER: 2 005 835 703 Page :

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TRAINING TO BE GIVEN 7 *sample to be approved. 112

*100% visual inspection.

PERIODIC MAINTENACE TO *sample to be approved.

7 112
BE DONE *100% visual inspection.

*sample to be approved.
TRAINING TO BE GIVEN 7 112
*100% visual inspection.

PERIODIC MAINTENACE TO *sample to be approved.

7 112
BE DONE *100% visual inspection.

sampling plan, work

instruction. (visual & 7 100 % visual inspection before 112
dimensional) despatch.

*to control the failure cause,

* follow the work instruction based on the packing standard
4 96
and packing standard. awareness, the failure cause to
be detect.

*to control the failure cause,

* induction training to be 4 based on the packing standard, 96
conduct. the failure cause to be detect.

*to control the failure cause,

* follow the work instruction 7 based on the packing standard, 112
and packing standard. the failure cause to be detect.

Page 22 of 24
 PROCESS FMEA Document No.: ASW / F / 85

Failure Mode and Effects Analysis Rev.No./Date: 01/10.6.2019

Original Date : 27.4.2019

DISTRIBUTION FMEA TYPE : PROCESS.

TO : SEG. NAME OF PRODUCT : DRIVE END SHIELD
BANGALORE. Component/Process : CASTING
PART NUMBER : 2 005 835 703

TASK : Wrong packing and wrong despatches are to be investigated and

CC: appropriate actions are to be fixed to avoid failures.

RESULTS : Risk priority index (RPN) higher than 125 have been identified and
ORIGINAL AT : listed in the enclosed sheet.
ASWINI ENTERPRISES, CHENNAI.

WORKING GROUP: MEASURES: Actions for improvement with responsibility and due date have been
1. PALANIAPPAN (PRODUCTION) proposed for causes with risk priority index (RPN) higher than 125.

2. BALAMURUGAN (QUALITY)
ENCLOSURE:
3. BALAJI (QUALITY) 1. FMEA summary
2. FMEA sheets
4. E.KUMAR (SUPERVISOR)

ELABORATION APPROVAL IMPLEMENTATION

MODERATOR TEAM LEADER HEAD OF DEPT RESP. PERSON

NAME R.BALAMURUGAN. R.BALAMURUGAN. A.PALANI. A.PALANI.

DEPARTMENT QUALITY QUALITY PRODUCTION. PRODUCTION.

DATE

SIGNATURE
 FMEA Change History

PART DESCRIPTION: DRIVE END SHIELD - 2 005 835 703

Revision No. Date Changes Changed by

00 27.4.2019 FIRST EDITION. QA

01 10.6.2019 DRAWING REVISED. QA