FMEA Sample

SIBILITY ACTI
POTENTIAL POTENTIAL RECOMM

Proc.No PROCESS POTENTIAL SE CLAS OC & ON
S NO. REQUIREMENT EFFECT OF CAUSE OF CURRENT PREVENTION CONTROL DET RPN ENDED SEV
. FUNCTION FAILURE MODE V S C TARGET TAKE
FAILURE FAILURE ACTION
COMP. N
DATE
Slight transport proble m Incoming

Quantity as per Quantity not as Incoming Inspection
1 inconvinience to 2 from 2 Inspection 7 28
Invoice per invoice Report
process supplier/customer Standard
A Portion of parts Incoming

Incoming Inspection
A-00 Incoming No Water mark Water Mark have to be 5 PH High / Low 6 Inspection 5
Report
reworked offline Standard
Incoming
Lot have to be Incoming Inspection
2 No Paint peel Off Paint peel off 6 PH High / Low 2 Inspection 5
reworked offline Report
Standard
Portion of parts to
Improper
be Incoming
processing/transpo Incoming Inspection
1 No Rust Rust Cleaning/Rework 3 7 Inspection 7 147
rt proble mfrom Report
instationand send Standard
supplier/customer
for processing
Portion of parts to
Improper
be Incoming
2 No Dust Dust Cleaning/Rework 3 5 Inspection 7
supplier/customer
for processing
Portion of parts to
Improper
be Incoming
3 No Dirt Dirt Cleaning/Rework 3 2 Inspection 7
supplier/customer
for processing
Partion of parts to Improper

Incoming
be Scrap and sent processing/transpo Incoming Inspection
4 No Dent & damage Dent & damage 7 2 Inspection 7
back to rt proble mfrom Report
Standard
Supplier/Customer supplier/customer
Portion of parts to
Improper
be Incoming
5 No Excess Oil Excess Oil Cleaning/Rework 3 2 Inspection 7
supplier/customer
for processing
Incoming
A-10
Inspection
Partion of parts to Improper
Incoming
Incoming be Scrap and sent processing/transpo Incoming Inspection
A-10 6 No Pitted Pitted 7 2 Inspection 7
Inspection back to rt proble mfrom Report
Standard
Supplier/Customer supplier/customer
Portion of parts to
Improper
be Incoming
7 No Burr Burr Cleaning/Rework 3 2 Inspection 7
supplier/customer
for processing
Portion of parts to
Improper
be Incoming
8 No Buffing Marks Buffing Marks Cleaning/Rework 3 2 Inspection 7
supplier/customer
for processing
Portion of parts to
Improper
be Incoming
9 No Grease Grease Cleaning/Rework 3 2 Inspection 7
supplier/customer
for processing
Portion of parts to
Improper
be Incoming
10 No Fint or Cotton Fint or Cotton Cleaning/Rework 3 2 Inspection 7
supplier/customer
for processing
Portion of parts to
Improper
be Incoming
11 No Carbon Carbon Cleaning/Rework 3 8 Inspection 7 168
supplier/customer
for processing
A Portion of part
Buffing not done Operation Inprocess Visual
1 No Rust Rust have to be 3 7 7
as per standard Standard Inspection
reworked Instation
A Portion of part
2 No Dust Dust have to be 3 7 7
reworked Instation
Buffing on
A-11
Parts
A Portion of part
3 No Spatter Spatter have to be 3 2 7
reworked Instation
A Portion of part
No Blackness on Blackness on Buffing not done Operation Inprocess Visual
4 have to be 3 2 7
surface surface as per standard Standard Inspection
reworked Instation
As per operation
Portion of part
Masking No Paint on Paint on masking Masking standard Inspection at
A-12 1 have to be 5 8
Fitment Masking Area area Loose/damage Unlading and unlaoding and final
reworked offline
final
Hanger
Preventive Inspection report for
Damage of maintenance and hanger and
4 8
Hangering Points inspection at unloading
unloading and inspection report
final
Hanger
Excess paint on maintenance and hanger and
4 8
Contact Points inspection at unloading
final
Portion of parts to
1 No Dull Finish Dull Finish 5
be Rework offline
Hanger
loose contact in- Preventive Inspection report for
between hanger maintenance and hanger and
4 8
contact point and inspection at unloading
part unloading and inspection report
final
Hanger
Quantity not as per
maintenance and hanger and
the specified 4 8
inspection at unloading
hanger design
final
Hanger
5 8
final
Hanger
5 8
final
Entire lot to be
2 DFT high 6
reworked
Hanger
Cleaning 5 8
final
Hanger
Quantity not as per
the specified 5 8
hanger design
final
DFT as per specks
Hanger
6 8
final
Hanger
6 8
final
Entire lot to be
3 DFT Low 6
reworked
Hanger
6 8
final
Hanger
Quantity not as per
the specified 6 8
hanger design
final
Hanger
6 8
final
Hanger
6 8
final
Portion of parts to
4 No Chemical Flow Chemical Flow 5
be Rework offline
Hanger
6 8
final
Hanger
Quantity not as per
the specified 6 8
hanger design
final
A-20 Loading
A-20 Loading
Hanger
6 8
final
Hanger
6 8
final
Portion of parts to
5 No Water mark Water Mark 5
be Rework offline
Hanger
6 8
final
Hanger
Quantity not as per
the specified 6 8
hanger design
final
Hanger
4 8
final
Hanger
4 8
final
Portion of parts to
6 No Scratch Scratch 7
be scraped
Hanger
4 8
final
Hanger
Quantity not as per
the specified 4 8
hanger design
final
Hanger
6 8
final
Hanger
6 8
final
Portion of parts to
7 No Touching Touching 5
be Rework offline
Hanger
6 8
final
Hanger
Quantity not as per
the specified 6 8
hanger design
final
Hanger
6 8
final
Hanger
6 8
final
Portion of parts to
8 No Air Pocket Air Pocket 5
be Rework offline
Hanger
6 8
final
Hanger
Quantity not as per
the specified 6 8
hanger design
final
Inprocess
As per Operation
Temp. - Low/High 7 Inspection & Poka 5
standard
Yoke alarm
As per Operation Inprocess

PH High / Low 7 5
standard Inspection
Portion of parts to
1 No Dust Dust 5
be Rework offline
Circulation
Pressure- 7 5
standard Inspection
High/Low
Inprocess
As per Operation
Dip time-High/Low 7 Inspection & PLC 1
standard
Control
Hot Water
A-30
Rinse
Inprocess
As per Operation
Temp. - Low/High 7 Inspection & Poka 5
standard
Yoke alarm

PH High / Low 7 5
standard Inspection
Portion of parts to
2 No Blister Blister 5
be Rework offline
Circulation
Pressure- 7 5
standard Inspection
High/Low
Inprocess
As per Operation
standard
Control
Total Alkanity not As per Operation Inprocess

9 5
as defined Standard Inspection
Inprocess
As per Operation
Temp Hig/Low 9 Inspection and 5
Standard
Poka yoke Alarm
A Portion of part Circulation Inlet

1 No Pin Hole Pin Hole have to be 5 Pressure not as 9 5
Standard Inspection
reworked offline defined
Inprocess
Dip time not as As per Operation
9 Inspection & PLC 1
defined Standard
Contorlled
As per Operation
Oil Content High 9 External Lab Test 9
Standard
Knock of
A-40 Degreasing
(KOD)

1 5
Inprocess
As per Operation
Standard
Poka yoke Alarm
Circulation Inlet
Lot have to be As per Operation Inprocess
1 No SST Failure SST Failure 6 Pressure not as 1 5
reworked offline Standard Inspection
defined
Inprocess
defined Standard
Contorlled
As per Operation
Standard
9 5
Inprocess
As per Operation
Standard
Poka yoke Alarm
A Portion of part Circulation Inlet

1 No Pin Hole Pin Hole have to be 5 Pressure not as 9 5
Standard Inspection
reworked offline defined
Inprocess
defined Standard
Contorlled
As per Operation
Standard
A-50 Degreasing

1 5
Inprocess
As per Operation
Standard
Poka yoke Alarm
Circulation Inlet
1 No SST Failure SST Failure 6 Pressure not as 1 5
defined
Inprocess
defined Standard
Contorlled
As per Operation
Standard

PH High / Low 9 5
Standard Inspection
Total Alkali not as As per Operation Inprocess

9 5
per speck Standard Inspection
A Portion of part
1 No Pin Hole Pin Hole have to be 5 Conductivity High 9 5
Standard Inspection
reworked offline
Poor Spray As per Operation Inprocess

9 5
Pressure Standard Inspection
Inprocess
Inspection & PLC
Spray time not as As per Operation
9 Conrolled 1
defined Standard
(Interlinked with dip
time)

PH High / Low 1 5
Standard Inspection

1 5
Water- Rinse Lot have to be As per Operation Inprocess

A-60 2 SST as per Req SST Fail 6 Conductivity High 1 5
-1 reworked offline Standard Inspection
1 5
Inprocess
Inspection & PLC
1 Conrolled 1
defined Standard
time)

PH High / Low 7 5
Standard Inspection

7 5
A Portion of part
3 No Paint Flow Paint Flow have to be 5 Conductivity High 7 5
Standard Inspection
reworked offline

7 5
Inprocess
Inspection & PLC
7 Conrolled 1
defined Standard
time)

PH High / Low 9 5
Standard Inspection

9 5
Conductivity High 9 5
Standard Inspection
A Portion of part
1 No Pin Hole Pin Hole have to be 5
reworked offline
Circulation
Pressure not as 9 5
Standard Inspection
defined
Water Flow rate As per Operation Inprocess

9 5
low Standard Inspection
Inprocess
Dip Time not as As per Operation
9 Inspection & PCL 1
deifined Standard
Controlled

PH High / Low 1 5
Standard Inspection

1 5

Standard Inspection
Water- Rinse Lot have to be

A-70 1 No SST Failure SST failure 6
-2 reworked offline
Circulation
Pressure not as 1 5
Standard Inspection
defined

1 5
Inprocess
deifined Standard
Controlled

PH High / Low 7 5
Standard Inspection

7 5

Standard Inspection
A Portion of part
1 No Paint Flow Paint Flow have to be
reworked offline
Circulation
Pressure not as 7 5
Standard Inspection
defined

7 5
Inprocess
deifined Standard
Controlled
Total Alkalli not as As per Operation Inprocess

1 5
defined Standard Inspection

Ph Nor as defined 1 5
Standard Inspection
Lot have to be
1 No SST Failure SST Failure
reworked offline
1 No SST Failure SST Failure
reworked offline
Curculation
Pressre not as 1 5
Standard Inspection
defined
Inprocess
defined Standard
Controlled
Surface
A-80 Conditioner
(Activation)
Total Alkalli not as As per Operation Inprocess

2 5

Ph Nor as defined 2 5
Standard Inspection
Lot have to be
1 No Paint Peeloff Paint Peel Off 6
reworked offline
Curculation
Pressre not as 2 5
Standard Inspection
defined
Inprocess
defined Standard
Controlled
Total Acidity not as As per Operation Inprocess

6 5
Oxidation Value As per Operation Inprocess

6 5
not as deifned Standard Inspection
Free Acifity Not as As per Operation Inprocess

6 5
Inprocess
As per Operation
Temp High/Low 6 Inspection & Poka 5
Standard
Yoke Alarm
Circulcation
Pressre not as 6 5
Standard Inspection
defined
Inprocess
DFT as per Lot have to be As per Operation
1 DFT Low 6 Dip Time High/Low 6 Inspection & PLC 1
Specks reworked offline Standard
Contorlled
Coating Weight As per Operation Inprocess

6 5
High/Low Standard Inspection
As per Operation
SEM High 6 3rd party test 9
Standard
Auto Dosing of Inprocess

As per Operation
Bonderite M AD 6 Inspection & PLC 1
Standard
131 not as defined Control

As per Operation
Bonderite2030 E 6 Inspection & PLC 1
Standard
not as deinfed Control
Sludge Content As per Operation

6 3rd party 9
high Standard

2 5
2 5

2 5
Inprocess
As per Operation
Standard
Yoke Alarm
Circulcation
Pressre not as 2 5
Standard Inspection
defined
Inprocess
Lot have to be As per Operation
1 No Paint Peel off Paint Peel Off 6 Dip Time High/Low 2 Inspection & PLC 1
Contorlled

2 5
As per Operation
Standard

As per Operation
Standard

As per Operation
Standard
2 3rd party 9
high Standard
A-90 Phosphating

6 5

6 5

6 5
Inprocess
As per Operation
Standard
Yoke Alarm
Circulcation
Pressre not as 6 5
Standard Inspection
defined
A Portion of part Inprocess

As per Operation
1 No Chemical Flow Chemical Flow have to be 5 Dip Time High/Low 6 Inspection & PLC 1
Standard
reworked offline Contorlled

6 5
As per Operation
Standard
As per Operation
Standard

As per Operation
Standard

6 3rd party 9
high Standard

1 5

1 5

1 5
Inprocess
As per Operation
Standard
Yoke Alarm
Circulcation
Pressre not as 1 5
Standard Inspection
defined
Inprocess
Lot have to be As per Operation
1 No SSt failure SST failure 6 Dip Time High/Low 1 Inspection & PLC 1
Contorlled
1 5
As per Operation
Standard

As per Operation
Standard

As per Operation
Standard

1 3rd party 9
high Standard

Total Acidity High 1 5
Standard Inspection
Lot have to be Poor Spray As per Operation Inprocess

1 No SST failure SST Failure 6 1 5
reworked offline Pressure Standard Inspection
Inprocess
Spray time not as As per Operation Inspection & PLC
1 1
defined Standard Contorl ( Interlinked
with dip time)

Standard Inspection
DI Water Portion of Parts to Poor Spray As per Operation Inprocess
A-100 2 No Blister Bilster 5 5 5
Rinse - I be reworked offline Pressure Standard Inspection
Inprocess
5 1
with dip time)

Standard Inspection
A Portion of part
2 No Chemical Flow Chemical Flow have to be 5 6 5
reworked offline
Inprocess
6 1
with dip time)

Standard Inspection

PH High / Low 6 5
Standard Inspection
A Portion of part
1 No Chemical Flow Chemical Flow have to be 5
reworked offline
Circulation
Pressure- 6 5
Standard Inspection
High/Low
Inprocess
As per Operation
Standard
Contorlled
DI Water
A-110
Rinse - II
A-110
Rinse - II

Standard Inspection

PH High / Low 5 5
Standard Inspection
Portion of Parts
2 No Blister Blister have to be 5
reworked offline
Circulation
Pressure- 5 5
Standard Inspection
High/Low
Inprocess
As per Operation
Standard
Contorlled

Standard Inspection

PH High / Low 1 5
Standard Inspection
Circulation
Pressure- 1 5
Standard Inspection
High/Low
Lot have to be
1 No SST failure SST failure 5
reworked offline
Inprocess
As per Operation
Standard
Contorlled
Continuous water As per Operation Inprocess

1 5
Flow low Standard Inspection
Exit spray
pressure not as 1 5
Standard Inspection
defined

Standard Inspection

PH High / Low 2 5
Standard Inspection
Circulation
Pressure- 2 5
Standard Inspection
High/Low
DI Water Lot have to be

A-120 1 No Paint peel Off Paint Peeloff 6
Rinse-III reworked offline
Inprocess
As per Operation
Standard
Contorlled

2 5
Exit spray
pressure not as 2 5
Standard Inspection
defined

Standard Inspection

PH High / Low 5 5
Standard Inspection
Circulation
Pressure- 5 5
Standard Inspection
High/Low
A Portion of part
reworked offline
Inprocess
As per Operation
Standard
Contorlled

5 5
Exit spray
pressure not as 5 5
Standard Inspection
defined
Inprocess
As per Operation
Dip Time Hig/Low 5 Inspection & PLC 1
Standard
Contorlled
Inprocess
Voltage not as As per Operation
defined Standard
Controlled
Inprocess
Anolyte
As per Operation Inspection & Poka
Conductivity nor 5 1
Standard Yoke auto add DI
as defined
water
Anolyte Flow not As per Operation Inprocess

5 5
Permeate As per Operation Inprocess

5 5
Generation low Standard Inspection
Paint Circulation As per Operation Inprocess
5 7
with stagnation Standard Inspection
DFT as per Lot have to be Paint conducitivity As per Operation Inprocess

1 DFT High 6 5 5
Specks reworked offline not as defined Standard Inspection
Pressure As per Operation Inprocess

5 5
difference high Standard Inspection

Backteria found 5 7
Standard Inspection
Ionic
As per Operation
Contamination 5 3rd Party 9
Standard
high
P/B Ratio not as As per Operation

5 3rd Party 9
defined Standard
As per Operation
Solvent high 5 3rd Party 9
Standard
Exit spray
pressure not as 5 5
Standard Inspection
defined
Inprocess
As per Operation
Standard
Contorlled
Inprocess
defined Standard
Controlled
Inprocess
Anolyte
as defined
water

6 5

6 5

6 7
DFT as per Lot have to be Paint conducitivity As per Operation Inprocess

1 DFT Low 6 6 5
Specks reworked offline not as defined Standard Inspection

6 5

Backteria found 5 7
Standard Inspection
Ionic
As per Operation
Standard
high
6 3rd Party 9
defined Standard
As per Operation
Standard
Exit spray
pressure not as 6 5
Standard Inspection
defined
Inprocess
As per Operation
Standard
Contorlled
Inprocess
defined Standard
Controlled
Inprocess
Anolyte
as defined
water

4 5

4 5

4 7
A Portion of part
Paint conducitivity As per Operation Inprocess
1 No Dull Finish Dull Finish have to be 5 4 5
not as defined Standard Inspection
reworked offline

4 5

Backteria found 5 7
Standard Inspection
Ionic
As per Operation
Standard
high

4 3rd Party 9
defined Standard
As per Operation
Standard
Exit spray
pressure not as 4 5
Standard Inspection
defined
Inprocess
As per Operation
Standard
Contorlled
Inprocess
defined Standard
Controlled
Inprocess
Anolyte
as defined
water

9 5

9 5

9 7
Cathod
A Portion of part
Electro Paint conducitivity As per Operation Inprocess
A-130 1 No Pin Hole Pin Hole have to be 5 9 5
Deposition not as defined Standard Inspection
reworked offline
(CED)

9 5

Backteria found 5 7
Standard Inspection
Ionic
As per Operation
Standard
high

9 3rd Party 9
defined Standard
As per Operation
Standard
Exit spray
pressure not as 9 5
Standard Inspection
defined
Inprocess
As per Operation
Standard
Contorlled
Inprocess
defined Standard
Controlled
Inprocess
Anolyte
as defined
water

7 5

7 5

7 7
A Portion of part
Paint conducitivity As per Operation Inprocess
1 No Paint Flow Paint Flow have to be 5 7 5
not as defined Standard Inspection
reworked offline
7 5

Backteria found 5 7
Standard Inspection
Ionic
As per Operation
Standard
high

7 3rd Party 9
defined Standard
As per Operation
Standard
Exit spray
pressure not as 7 5
Standard Inspection
defined
Inprocess
As per Operation
Standard
Contorlled
Inprocess
defined Standard
Controlled
Inprocess
Anolyte
as defined
water
1 5

1 5

1 7
Lot have to be Paint conducitivity As per Operation Inprocess

1 No SST Failure SST failure 6 1 5
reworked offline not as defined Standard Inspection

1 5

Backteria found 5 7
Standard Inspection
Ionic
As per Operation
Standard
high

1 3rd Party 9
defined Standard
As per Operation
Standard
Exit spray
pressure not as 1 5
Standard Inspection
defined
Inprocess
As per Operation
Standard
Contorlled
Inprocess
defined Standard
Controlled
Inprocess
Anolyte
as defined
water

2 5

2 5

2 7
Lot have to be Paint conducitivity As per Operation Inprocess

1 No Paint Peel Off Paint Peel Off 6 2 5
reworked offline not as defined Standard Inspection

2 5
Backteria found 5 7
Standard Inspection
Ionic
As per Operation
Standard
high

2 3rd Party 9
defined Standard
As per Operation
Standard
Exit spray
pressure not as 2 5
Standard Inspection
defined

PH not as required 7 5
Standard Inspection

Non Volatility High 7 5
Standard Inspection
Conductivity not as As per Operation Inprocess

7 5
A Portion of Parts
1 No Paint Flow Paint Flow to be reworked 5
offline
Circulation
Pressure not as 7 5
Standard Inspection
defined
Inprocess
defined Standard
Ccntorlled
Exit Pressure not As per Operation Inprocess

7 5
A-140 Ultra Filter- I

Standard Inspection

Standard Inspection

5 5
A Portion of part
reworked offline
Circulation
Pressure not as 5 5
Standard Inspection
defined
Inprocess
defined Standard
Ccntorlled

5 5

Standard Inspection
Standard Inspection

7 5
A Portion of parts
1 No Paint Flow Paint Flow have to be 5
reworked offline
Circulation
Pressure not as 7 5
Standard Inspection
defined
Inprocess
defined Standard
Ccntorlled

7 5
A-150 Ultra Filter- 2

Standard Inspection

Standard Inspection

5 5
2 No Blister Blister 5
Circulation
Pressure not as 5 5
Standard Inspection
defined
Inprocess
defined Standard
Ccntorlled

5 5

Standard Inspection

Standard Inspection

7 5
A Portion of parts
1 No Paint Flow Paint Flow have to be 5
reworked offline
Circulation
Pressure not as 7 5
Standard Inspection
defined
Inprocess
defined Standard
Ccntorlled

7 5
A-160 Ultra Filter-3

Standard Inspection
Standard Inspection

5 5
A Portion of part
reworked offline
Circulation
Pressure not as 5 5
Standard Inspection
defined
Inprocess
defined Standard
Ccntorlled

5 5

Standard Inspection

PH High / Low 1 5
Standard Inspection
Circulation
1 No SST failure SST failure 6 Pressure- 1 5
High/Low
Inprocess
As per Operation
Standard
Controlled
Exit spray
pressure not as 1 5
Standard Inspection
defined

Standard Inspection

PH High / Low 7 5
Standard Inspection
A Portion of parts Circulation

DI Water As per Operation Inprocess
Lot 2 No Paint Flow Paint Flow have to be 5 Pressure- 7 5
Rinse-IV Standard Inspection
reworked offline High/Low
Inprocess
As per Operation
Standard
Controlled
Exit spray
pressure not as 7 5
Standard Inspection
defined

Standard Inspection

PH High / Low 5 5
Standard Inspection
A Portion of part Circulation

3 No Blister Blister have to be 5 Pressure- 5 5
Standard Inspection
reworked offline High/Low
Inprocess
As per Operation
Standard
Controlled
Exit spray
pressure not as 5 5
Standard Inspection
defined
A Portion of parts
Air not blown on As per Operation Inspection at
1 No Water Mark Water Mark have to be 5 6 8 240
part properly Standard unloading and final
reworked offline
Air Blow
A-180
station
A Portion of parts
Air not blown on As per Operation Inspection at
2 No Paint Flow Paint Flow have to be 5 7 8
part properly Standard unloading and final
reworked offline
Inprocess
Ovan Temp As per Operation
4 Inspection & Poka 5
High/Low Standard
Yoke Alarm
Inprocess
Baking Time As per Operation
High/Low Standard
contorller
Inprocess
A Portion of part Heat Exchager
As per Operation Inspection & PLC
1 No Dull finish Dull Finish have to be 5 Temperature not 4 2
Standard Contorlled and stop
reworked offline as defined
line
EMT not as As per Operation Inhouse 3 monthly

4 9
defined Standard plan
Inprocess
Flight bar out time As per Operation
not as defined Standard
Contorlled
Inprocess
High/Low Standard
Yoke Alarm
Inprocess
Naking Time As per Operation
High/Low Standard
contorller
Inprocess
Heat Exchager
Lot have to be As per Operation Inspection & PLC
1 No Paint peel off Paint Peel Off 6 Temperature not 2 2
reworked offline Standard Contorlled and stop
as defined
line

2 9
Inprocess
Contorlled
Inprocess
High/Low Standard
Yoke Alarm
Inprocess
High/Low Standard
contorller
Inprocess
Heat Exchager
Lot have to be As per Operation Inspection & PLC
1 No SST Failure SST failure 6 Temperature not 1 2
reworked offline Standard Contorlled and stop
as defined
line

1 9
Inprocess
Contorlled
A-190 Baking
Inprocess
High/Low Standard
Yoke Alarm
Inprocess
High/Low Standard
contorller
Inprocess
Heat Exchager
DFT as per Lot have to be As per Operation Inspection & PLC
1 DFT Low 6 Temperature not 6 2
Specks reworked offline Standard Contorlled and stop
as defined
line

6 9
Inprocess
Contorlled
Inprocess
High/Low Standard
Yoke Alarm
Inprocess
High/Low Standard
contorller
Inprocess
1 No Blister Blister have to be 5 Temperature not 5 2
line
5 9
Inprocess
Contorlled
Inprocess
High/Low Standard
Yoke Alarm
Inprocess
High/Low Standard
contorller
Inprocess
1 No Dust Dust have to be 5 Temperature not 7 2
line

7 9
Inprocess
Contorlled
A Portion of part
Final Inspection
No Blister Blister have to be 5 Oliy Part Loaded 5 Visual 8 200
Standard
reworked offline
A Portion of part
Air Blowing not Final Inspection
No Pin Holes Pin Holes have to be 5 9 Visual 8 360
Proper Standard
reworked offline
A Portion of part
Final Inspection
No Dust Dust have to be 5 Oliy Part Loaded 7 Visual 8 280
Standard
reworked offline
A Portion of part Air Blowing not

Final Inspection
No Touchmark Touchmark have to be 5 Proper / part 6 Visual 8 240
Standard
reworked offline hanginf not proper
A Portion of part
No Dull Finish Dull Finish have to be 5 4 Visual 8 160
Proper Standard
reworked offline
A Portion of part
Not Proper Final Inspection
No Chemical Flow Chemical Flow have to be 5 6 Visual 8 240
Handling Standard
reworked offline
A Portion of part
Final Inspection
No paint flow paint flow have to be 5 Rusty Part Loaded 7 Visual 8 280
Standard
reworked offline
A Portion of part
Final Inspection
A- 200 Unloading No Water Mark Water Mark have to be 5 6 Visual 8 240
Standard
reworked offline
A Portion of part
Final Inspection
No Unpainted Unpainted have to be 5 6 Visual 8 240
Standard
reworked offline
A Portion of parts
Final Inspection
No Scratch Scratch have to be 7 4 Visual 8 224
Standard
scrapped
A Portion of parts
No Dent & Final Inspection
Dent & Damage have to be 7 6 Visual 8 336
Damage Standard
scrapped
A Portion of part
Final Inspection
No Air Pocket Air Pocket have to be 5 6 Visual 8 240
Standard
reworked offline
Lot have to be Final Inspection

No Paint Peel off Paint Peel off 6 2 Visual 8 96
Lot have to be Final Inspection Final Inspection

DFT High 6 5 6 180
reworked offline Standard Report
DFT As per
Specks

DFT Low 6 6 6 216
A Portion of part
Final Inspection
1 No Blister Blister have to be 5 Oliy Part Loaded 5 Visual 8 200
Standard
reworked offline
A Portion of part
2 No Pin Holes Pin Holes have to be 5 9 Visual 8 360
Proper Standard
reworked offline
A Portion of part
Final Inspection
3 No Dust Dust have to be 5 Oliy Part Loaded 7 Visual 8 280
Standard
reworked offline
A Portion of part Air Blowing not

Final Inspection
4 No Touchmark Touchmark have to be 5 Proper / part 6 Visual 8 240
Standard
reworked offline hanginf not proper
A Portion of part
5 No Dull Finish Dull Finish have to be 5 4 Visual 8 160
Proper Standard
reworked offline
A Portion of part
Not Proper Final Inspection
6 No Chemical Flow Chemical Flow have to be 5 6 Visual 8 240
Handling Standard
reworked offline
A Portion of part
Final Inspection
7 No paint flow paint flow have to be 5 Rusty Part Loaded 7 Visual 8 280
Standard
reworked offline
A Portion of part Improper

Final Inspection
8 No Water Mark Water Mark have to be 5 Processing at CED 6 Visual 8 240
Standard
reworked offline Process

Final Inspection
9 No Unpainted Unpainted have to be 5 Processing at CED 6 Visual 8 240
Standard
A Portion of parts Improper

Final Final Inspection
A-220 10 No Scratch Scratch have to be 7 Processing at CED 4 Visual 8 224
Inspection Standard
scrapped Process
A Portion of parts Improper

No Dent & Final Inspection
11 Dent & Damage have to be 7 Processing at CED 6 Visual 8 336
Damage Standard
scrapped Process

Final Inspection
12 No Air Pocket Air Pocket have to be 5 Processing at CED 6 Visual 8 240
Standard
Improper
13 No Paint Peel off Paint Peel off 6 Processing at CED 2 Visual 8 96
Process
Improper
14 DFT High 6 Processing at CED 5 6 180
Process
DFT As per
Specks
Specks
Improper
15 DFT Low 6 Processing at CED 6 6 216
Process
Improper
16 No Adhesion fail Adhesion fail 6 Processing at CED 7
Process
No Pencil Improper
Pencil Hardness Lot have to be Final Inspection Final Inspection
17 Hardness Test 6 Processing at CED 7
Test Fail reworked offline Standard Report
Fail Process
Improper
No Rubbing Test Lot have to be Final Inspection Final Inspection
18 Rubbing Test Fail 6 Processing at CED 7
Fail reworked offline Standard Report
Process
Improper
19 No SST Fail SST life less 6 Processing at CED 1 3rd Part Test 9
Process
A Portion of parts
Packing not as per Packing
A-230 Packing 1 No Scratch Scratches have to be 7 4 Visual 7
standard Standard
scrapped
Partion of part
1 No Mixing Mixing 7 Less Awareness 2 As per Standard Visual 7 98
reject
A-240 Dispatch
QTY as per
QTY not to be By work
2 invoice Less/ Min Inconvinience 2 Less Awareness 2 Visual 7 28
Less/ More Instruction
More
Sr. No. Symbol Description Rev No Rev Details Rev Dt PREPARED BY Approved By
1 * Poka Yoke 1 Cust prob(sludge on bolt ) in A(200) process added 5.2.19 Shubham Pankaj Patil
27.03.201
2 Critical characteristics 2 FILTER CLEANING POINT ADDED IN BAKING OPERATION Shubham Pankaj Patil
9
18.04.201
3 DURING INCOMING CARBON DEFECT NOT CHECK Shubham Pankaj Patil
9
10.05.201
4 DURING INCOMING WATER PH CHECK Shubham Pankaj Patil
9
15.05.201
5 COHERNECE DONE AS PER PLAN Shubham Pankaj Patil
9
6 CONTACT POINT OF HANGER IN OP A-20 24.5.2018 Shubham Pankaj Patil
7 HANGER FIXING POINT ADDED IN OP A-20 1.6.2019 Shubham Pankaj Patil
8 Hanger maintenance point added in OP-A20 for dust problem. 22.6.2019 Shubham Pankaj Patil
9 Hanger Selection point added in OP-A20 for pin holes problem. 1.7.2019 Shubham Pankaj Patil
10 Air blowing paint flow defect point added in OP-180 29.7.2019 Shubham Pankaj Patil
11 DIESAL CLEANING FOR PAINT PEEL OFF PROBLEM ADDED IN OP. A-20 5.8.2019 Shubham BIPIN TIWARI
12 FMEA REVIEW & Less Contact point Point added in OP-A20 25.9.2019 Shubham Pankaj Patil
OCC DET RPN
d By
atil
atil
atil
atil
atil
atil
atil
atil
atil
atil
WARI
atil

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SIBILITY ACTI

POTENTIAL POTENTIAL RECOMM

Slight transport proble m Incoming

A Portion of parts Incoming

Partion of parts to Improper

As per Operation Inprocess

As per Operation Inprocess

Total Alkanity not As per Operation Inprocess

A Portion of part Circulation Inlet

Total Alkanity not As per Operation Inprocess

A Portion of part Circulation Inlet

Total Alkanity not As per Operation Inprocess

As per Operation Inprocess

Total Alkali not as As per Operation Inprocess

Poor Spray As per Operation Inprocess

As per Operation Inprocess

Total Alkali not as As per Operation Inprocess

Water- Rinse Lot have to be As per Operation Inprocess

As per Operation Inprocess

Total Alkali not as As per Operation Inprocess

Poor Spray As per Operation Inprocess

As per Operation Inprocess

Total Alkali not as As per Operation Inprocess

Water Flow rate As per Operation Inprocess

As per Operation Inprocess

Total Alkali not as As per Operation Inprocess

As per Operation Inprocess

Water- Rinse Lot have to be

Water Flow rate As per Operation Inprocess

As per Operation Inprocess

Total Alkali not as As per Operation Inprocess

As per Operation Inprocess

Water Flow rate As per Operation Inprocess

Total Alkalli not as As per Operation Inprocess

As per Operation Inprocess

Total Alkalli not as As per Operation Inprocess

As per Operation Inprocess

Total Acidity not as As per Operation Inprocess

Oxidation Value As per Operation Inprocess

Free Acifity Not as As per Operation Inprocess

Coating Weight As per Operation Inprocess

Auto Dosing of Inprocess

Auto Dosing of Inprocess

Sludge Content As per Operation

Total Acidity not as As per Operation Inprocess

Free Acifity Not as As per Operation Inprocess

Coating Weight As per Operation Inprocess

Auto Dosing of Inprocess

Auto Dosing of Inprocess

Total Acidity not as As per Operation Inprocess

Oxidation Value As per Operation Inprocess

Free Acifity Not as As per Operation Inprocess

A Portion of part Inprocess

Coating Weight As per Operation Inprocess

Auto Dosing of Inprocess

Sludge Content As per Operation

Total Acidity not as As per Operation Inprocess

Oxidation Value As per Operation Inprocess

Free Acifity Not as As per Operation Inprocess

Auto Dosing of Inprocess

Auto Dosing of Inprocess

Sludge Content As per Operation

As per Operation Inprocess

Lot have to be Poor Spray As per Operation Inprocess