MAHARASHTRA POLYMER PRODUCTS

POTENTIAL FAILURE MODE AND EFFECT ANALYSIS (PROCESS FMEA)

Part No. 12462048/12462049 Process Responsibility :- MR.KAMLESH FMEA Number: PFMEA/01/2017

Drg. No -- Team:- Mr.KAMLESH,KUSHAL & VIJAY Prepared by: MR PRAVIN
Rev. No 0 Date (Orig.) 10/2/2017
Part Name COMFORT RUBBER BEADING Key Date- 10.02.2017 Date (Rev.) 0

C Potential O Current D
Recommend Action Results
Process Potential Potential S Cause(s)/ c e R.
l Process ed Responsibility
Function/ Failure Effect(s) of e Mechanism(s) c t P.
a Controls Actions & Target Actions S O D R.
Require- Mode Failure v s of Failure u Prevention e N. Date Taken e c e P.
ments s r 'A' type c v c t N.
b)Inspection Proper 1/2/2017 Inspected 6 2 1 12
Raw Materials a) Poor Handling 2 During 1 12 Inspection Properly
10 Reciving of Raw Damage Or
Properties Will 6 b),Improper Storage , c) 2 Un Loading, 1 12
materials in Store Deteratuion
be affected Slow movement 2 c)Regular Check 4 48
FIFO
Verification 5/2/2017 Process 3 3 2 18
Verification Of
2 18 as per verified
20 Inspection Of Raw Material not as per Compound Will MTC In house
3 Inspection not effective 3 4 36 process
material specification be affected Tests Reputable
2 18
Supplier
Batch Card
Lack of Proper Instructio 4 Periodic 4 48
30 Weighing of Compound Will
Excess or less 3 Weighing Balance Out of 2 Calibration 2 12
Ingredient s for batch be affected
calibration 2 Mixing Check 3 18 Calibration
sheet checking 5/2/2017 Calibrated 3 4 4 48
Dump Temp out of
Compounding 2 2
specfication 12 12
40. Kneader Mixing Improper Dispersion properties Will 3 2 Mixing sequence 2
Mixing Sequence 36
be affeted 4 sheet display in 3 Proper Inspected
Improper
mixing area Inspection 10/2/2017 Properly 3 2 2 12
Compounding
50. Sheeting of Mixed Time lag between Fallow FIFO
properties Will 3 Time lag 4 3 36 Check Time
Stock Dumping and Sheeting system
be affeted lag 10/2/2017 checked 3 4 3 36
Compounding Monitorng by 5A
60 Maturation (Curring Inadequate time Inadequate Stock 3 3 27
properties Will 3 Supervisor use
Chemical) contamination Wet or Dusty Environment 2 3 18 Check
be affeted of fan as needed
Environment 9/2/2017 Checked 3 3 3 27
70 Weighing of Fine Compounding Digital
Improper dispersion
\Chemicals and Mix final properties Will 3 Milling Inadequate 3 weinghing 3 27 Check
of Chemicals added
Batch be affeted balance used Weighing 9/2/2017 Checked 3 3 3 27
Inconsistency in
80 Re Milling and Cut Thickness not ok Tranning to
feeding 3 Deficiency in skill of cutting 2 3 18 Check
Strips Width not ok operator
Extruder Thickness 9/2/2017 checked 3 2 3 18
90. Store and test Rheometric Values not Defective 3 Testing Each 12 Test Each
4 Raw materials Processing 1
compound accepted Product 3 Batch 12 Batch 9/2/2017 Tested 4 3 1 12

Prepared By: Page 1 of 3 Approved By:

 POTENTIAL FAILURE MODE AND EFFECT ANALYSIS (PROCESS FMEA)

Part No. 12462048/12462049 Process Responsibility :- MR.KAMLESH FMEA Number: PFMEA/01/2017

Drg. No -- Team:- Mr.KAMLESH,KUSHAL & VIJAY Prepared by: MR PRAVIN
Rev. No 0 Date (Orig.) 10/2/2017
Part Name COMFORT RUBBER BEADING Key Date- 10.02.2017 Date (Rev.) 0

C Potential O Current D
Recommend Action Results
Process Potential Potential S Cause(s)/ c e R.
l Process ed Responsibility
Function/ Failure Effect(s) of e Mechanism(s) c t P.
a Controls Actions & Target Actions S O D R.
Require- Mode Failure v s of Failure u Prevention e N. Date Taken e c e P.
ments s r 'A' type c v c t N.
Product Life Contamination rubber , 1 2 3
15
Over Size /Under Size, Impaired 5 Improper setting ,pre 3 SOP or work 3
30
Wrong Shape ,surface, Fitness Problem 4 mature scorching 3 Instruction 3
100. Extrusion 36
Blemishes, Product life 4 ,speed,shadenot matching, 3 dispalyed at 3
36 24
Blisster Impaired poor 5 Die problem varitation in 2 work station 3
30 Check As per
aesthetics Mixing perpority 2 3
SOP 9/2/2017 Checked 5 1 3 15
Maitained Record
Surface hardning not deform product
110, Shocking Heating 4 zone Temperture 3 Hourly record of 3 36 Temperatur
adequate dull surface
tempreture e hourly 9/2/2017 Recorded 4 3 3 36

Prepared By: Page 2 of 3 Approved By:

 POTENTIAL FAILURE MODE AND EFFECT ANALYSIS (PROCESS FMEA)

Part No. 12462048/12462049 Process Responsibility :- MR.KAMLESH FMEA Number: PFMEA/01/2017

Drg. No -- Team:- Mr.KAMLESH,KUSHAL & VIJAY Prepared by: MR PRAVIN
Rev. No 0 Date (Orig.) 10/2/2017
Part Name COMFORT RUBBER BEADING Key Date- 10.02.2017 Date (Rev.) 0

C Potential O Current D
Recommend Action Results
Process Potential Potential S Cause(s)/ c e R.
l Process ed Responsibility
Function/ Failure Effect(s) of e Mechanism(s) c t P.
a Controls Actions & Target Actions S O D R.
Require- Mode Failure v s of Failure u Prevention e N. Date Taken e c e P.
ments s r 'A' type c v c t N.
Deformed Temperture at different 3 3 36
Under cure over cure 4 Maitained
120. Micro wave & Hot Product Dull Zones Magnetron 3 3 36
Dimension Out of 4 Hourly record of Record
Air Oven surface Fiting Intensity,Profile Position on 3 2 24
Specification 4 tempreture Temperatur
problem belt compound problem 3 2 24
e hourly 9/2/2017 Recorded 4 3 3 36
Deformation in Temperture
High temperture of Water 3 30
130. Cool by water profile 5 Monitoring 2 Monitor
Inadequate ,spray nozzle chocked, 3 45
Spraying ,customer 5 ,preventative 3 water flow
scale formation in pipes 3 45
Dissatisfication Maintenance and temp 9/2/2017 checked 5 3 2 30
140. Pass through Skill of the Checking
Section varitation High rejection 5 Speed not Synchronised 4 2 40
caterpiller Operator Continously 9/2/2017 checked 5 4 2 40
Work
Defective Portion not Fitment
150. Online cutting 3 Operator Negligence 3 onstruction and 2 18
removed problem Inspecting
Startof Approval
Process 9/2/2017 checked 3 3 2 18
Verification Of
MTC In house 2 24
160 Inspection Of Rubber Material not as per Fitment
4 Inspection not effective 3 Tests and 4 48
Profile specification problem
Maintein the 2 24 Test as per
record specification 9/2/2017 checked 4 3 2 24
Defieciency in
Inprocess
170. Resizing Wrong length function on 3 Wrong cutting position 2 3 36 Inspecting in
inspection
fitting process 9/2/2017 checked 3 2 3 36
Defective lot May get Customer Final
3 Samplling inspection 5 AQL Level 2 30
accepted Dissatisfaction isnpection 9/2/2017 checked 3 5 2 30
190. Cleaning Packing & Packing Standard Not Mis placement 4 Packing Material , 3 Inspection Work 4 48
Inspection in
Labelling Fallow Damage 5 Work instruction 4 instruction 2 40
process 9/2/2017 inspected 4 3 4 48

Prepared By: Page 3 of 3 Approved By: