Professional Documents
Culture Documents
Occurrence
Detection
Occurrence
Severity
Responsibility
Detection
Class
Severity
Process Function Potential Failure Potential Cause(s) / Mechanism(s) Recommended
RPN
Opn Process Seq Potential Effects of Failure Current Process Controls prevention Current Process Controls detection and target
RPN
Requirements Mode. of Failure Actions* Actions taken
completion date
6 3
Down stream operation :
100% parts may have to be reworked 5 Casting damage 3 Dedicated trolley with separator
offline
1) To meet the Assy :
1 Fettling Not done properly 3 Trained Operator
customer Damage when receive NA
200% checked by inspector 6 108
specification for good part Customer :
part A Portion of production run may have to 6 Operator loading skill 2 Dedicated trolley with separator
be scrapped
End User:
5 While transportation 3 Standardised vehicle transport
Degradation of secondary function
6 3
End User:
1
No effect
OPERATION NO. #15 Shift Code Marking
6 3
Assy :
No Date code. 1 Wrong setting 3 Allocated or Identified location
Nil
Customer :
Lack of traceability 6
End User:
Nil 1
End User:
Nil 1
End User:
Nil 1
OPERATION NO. #20 LEFT HAND SIDE & RIGHT HAND SIDE -1 SETUP
6 3
Down stream operation: Not able to
6 No machining Allowance 2 Insp. Done at casting stage
machine (non clearance)
Milling Height over size
Assy: NA 1 Wrong loading 3 Nil 6 108
Gauge checked by operator
Customer:Assembly problem 6 Uneven clamping 3 Preventive maintanence
Established tool change frequency and
End User: Nil 1 Inserts worn out 2
specify in Opn.std
1) Milling Height
31.00±0.25, wrong tool offset 2 Program locked
68.18 ±0.2, Established tool change frequency and
Build up edge 3
72.93 ±0.2, specify in Opn.std
3.57±0.25
6 3
Down stream operation: Nil 1 Bend in the casting 3 Insp. Done at casting stage
Milling Height under Guide pin available in fixture to guide the
Assy: NA 1 Wrong loading 3 Gauge checked by operator 6 108
size part while loading
Customer: May affect / disturb at
6 Uneven clamping 3 preventive maintanence
assembly
End User: Nil 1 wrong tool offset 2 Program locked
6 3
Opn:20A) Milling
Down stream operation: Nil 1 Bend in the casting 3 Insp. Done at casting stage
6 3
Assy: NA 1 No machining Allowance 2 Insp. Done at casting stage Plug gauge check by operator. Diameter 6 72
I) Drill dia oversize is controlled within ± 0.05 for
Customer: Part strengthen not good while
6 Burr entrapment into tool holder 2 Coolant spray in tool holder further process control
running
End User: degradation of secondary
6 Wrong tool selection 2 Tool issue only as per tools list
function
1) Diameter Ø8.6 Spindle runout 2 preventive maintenance
6 2
Down stream operation:
1 Tool wear 2 Tool life monitoring provided
2nd setup machining cannot be done
Plug gauge check by operator. Diameter
II) Drill dia undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list is controlled within ± 0.05 for 6 72
further process control
Customer: Assembly cannot be done 6
6 2
6 2
Down stream operation:
1 Build up edge 2 Tool life monitoring provided
Thread cannot be formed
1
Action Results
Occurrence
Detection
Occurrence
Severity
Responsibility
Detection
Class
Severity
Process Function Potential Failure Potential Cause(s) / Mechanism(s) Recommended
RPN
Opn Process Seq Potential Effects of Failure Current Process Controls prevention Current Process Controls detection and target
RPN
Requirements Mode. of Failure Actions* Actions taken
completion date
6 3
6 3
Down stream operation:
1 Tool wear 2 Tool life monitoring provided
Nil
20C) ø6.0/ø7
Drilling II) Drill dia undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Core plug gauge check by operator 6 108
Established cutting parameters and
Customer: Bolt will not enter 6 Spindle speed / Feed rate high 3
program locked
6 3
l) depth Undersize Assy: Nil 1 Tool wear 3 Tool life monitoring provided FPG check by operator 6 108
II) Depth oversize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list FPG check by operator 6 72
Customer:Air & Fuel flow get affected 6 Wrong tool offset 2 Program locked
6 3
6 3
Down stream operation: Nil 1 Drill dia undersize 3 Tool life monitoring provided
Establish tool change frequency and
1) M8x1 6H Thread Assy: NA 1 Build up edge 3
specify in Opn.std
size
ll) M8x1 6H thread Go
( 1 places ) Customer:Filter not assemble 6 Coolant not flow 2 Flush coolant used to remove burr SPG check by operator 6 108
not answering
End User: Nil 1 Burr entrapment into tool holder 2 Coolant spray in tool holder
6 3
6 3
Down stream operation:
1 Resting pads not in same plane 2 Preventive maintanence
Nil
Assy: NA 1 Uneven clamping 2 Clamping pressure established
3) Position Position
Customer: Component getting disturbed while Ensure proper clamping of component Receiver Gauge checked by operator 6 108
0.2 wrt AB Out of spec 6 2
Cant able to assy the mating part machining against resting as per OS
Customer: Ensure proper adherance of tool life as
6 Position not ok 2
Cant able to assy the mating part per OS
6 3
Down stream operation:
1 No machining Allowance 2 Insp. Done at casting stage
Nil
6 3
Down stream operation:
1 Build up edge 2 Tool life monitoring provided
Nil
II) Groove ID undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Gauge check by operator 6 108
Established cutting parameters and
Customer: Seal will not assemble 6 Spindle speed / Feed rate high 3
program locked
6 3
Down stream operation:
1 No machining Allowance 2 Insp. Done at casting stage
Nil
6 3
Down stream operation:
1 Tool wear 2 Tool life monitoring provided
Nil
II) Groove width Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Gauge check by operator 6 108
undersize
Established cutting parameters and
Customer: Seal will not assemble 6 Improper Spindle speed / Feed rate 3
program locked
6 2
Down stream operation:
1 No machining Allowance 2 Insp. Done at casting stage
Nil
2
Action Results
Occurrence
Detection
Occurrence
Severity
Responsibility
Detection
Class
Severity
Process Function Potential Failure Potential Cause(s) / Mechanism(s) Recommended
RPN
Opn Process Seq Potential Effects of Failure Current Process Controls prevention Current Process Controls detection and target
RPN
Requirements Mode. of Failure Actions* Actions taken
completion date
6 2
Down stream operation:
1 Tool wear 2 Tool life monitoring provided
Nil
II) Groove depth Assy: NA 1 Wrong tool offset 2 Program locked Gauge check by operator 6 72
undersize
Customer: Seal will not assemble
6 Wrong tool selection 2 Tool issue only as per tools list
properly
6 2
Down stream operation:
1 Built-up edge 2 Tool life monitoring provided
Nil
20E) ø13.50
Cutting parameter established during
Grooving Assy: NA 1 Spindle speed & feed 2
trials and program locked
I) Radius oversize Inspection by inspector as per QCPC 6 72
Customer: Seal will damaged 6 Wrong tool selection 2 Tool issue only as per tools list
II) Radius undersize Assy: NA 1 Wrong tool offset 2 Program locked Inspection by inspector as per QCPC 6 72
Customer: Seal will damaged 6 Wrong tool selection 2 Tool issue only as per tools list
6 2
Down stream operation:
1 Build up edge 2 Tool life monitoring provided
Nil
I) Chamfer depth
Assy: NA 1 Wrong tool offset 2 Program locked Inspection by inspector as per QCPC 6 72
oversize
Customer: Seal will not assemble
6 Wrong tool selection 2 Tool issue only as per tools list
properly
End User: degradation of secondary
6
function
5) Chamfer depth
6 2
Down stream operation:
1 Tool wear 2 Tool life monitoring provided
Nil
II)Chamfer depth Assy: NA 1 Wrong tool offset 2 Program locked Inspection by inspector as per QCPC 6 72
undersize
Customer: Seal will not enter Into the
6 Wrong tool selection 2 Tool issue only as per tools list
groove
6 2
Down stream operation:
1 Build up edge 2 Tool life monitoring provided
Nil
I) Chamfer angle more
6) Chamfer angle Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Inspection by inspector as per QCPC 6 72
or less
Customer: Seal will not assemble
6 Tool wear 2 Tool life monitoring provided
properly
End User: degradation of secondary
6
function
6 3
6 3
Coolant secondary filter provided &
Down stream operation: Nil 1 Coolant concentration 2 Before coolant top up, check coolant
concentricity through refractor meter
Establish tool change frequency and
Surface finish out of Assy: NA 1 Tool wear 2
specify in Opn.std Inspection by inspector as per QCPC 6 108
spec
Customer:
6 Less Coolant flow 2 Failsafe alarm available in machine
Improper sealing
End User: Nil 1 Spindle speed / Feed rate high 3 Program locked
II) Drill dia undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Core plug gauge check by operator 6 108
Established cutting parameters and
Customer: Bolt will not enter 6 Spindle speed / Feed rate high 3
program locked
6 3
6 3
Down stream operation: Nil 1 Build up edge 3 Tool life monitoring provided
Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list
l) M10x1 6H thread
SPG check by operator 6 108
damage Coolant level indicator available and
Customer: Filter not assemble 6 Coolant not flow 2
machine stops on low level
End User: Nil 1 Burr entrapment into tool holder 2 Coolant spray in tool holder
6 3
Down stream operation: Nil 1 Drill dia undersize 3 Tool life monitoring provided
Establish tool change frequency and
1) M10x1 6H Thread Assy: NA 1 Build up edge 3
specify in Opn.std
size
ll) M10x1 6H thread Go
( 3 places ) Customer:Filter not assemble 6 Coolant not flow 2 Flush coolant used to remove burr SPG check by operator 6 108
not answering
End User: Nil 1 Burr entrapment into tool holder 2 Coolant spray in tool holder
6 3
3
Action Results
Occurrence
Detection
Occurrence
Severity
Responsibility
Detection
Class
Severity
Process Function Potential Failure Potential Cause(s) / Mechanism(s) Recommended
RPN
Opn Process Seq Potential Effects of Failure Current Process Controls prevention Current Process Controls detection and target
RPN
Requirements Mode. of Failure Actions* Actions taken
completion date
6 3
Down stream operation:
1 Resting pads not in same plane 2 Preventive maintanence
3) Position 2nd setup operation cannot be done
Ø0.6 wrt JDA Position First off Inspection/ Interposition gauge
Assy: NA 1 Uneven clamping 3 preventive maintanence 6 108
Ø0.6 wrt FDA Out of spec check by operator
Ø0.6 wrt EAH Customer: Component getting disturbed while Ensure proper clamping of component
6 2
Cant able to assy the mating part machining against resting as per OS
End User: Nil 1
6 3
Down stream operation: Nil 1 Build up edge 3 Tool life monitoring provided
11.10 + 0.1 Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list
intersection dia SPG check by operator 6 108
oversize Customer: O ring seat not properly 6 Spindle runout 2 Preventive maintanence
Down stream operation: Nil 1 Form tool intersection dia undersize 3 Tool life monitoring provided
11.10 + 0.1
Establish tool change frequency and SPG check by operator 6 108
intersection dia Assy: NA 1 Build up edge 3
specify in Opn.std
undersize
Customer:O ring seat not properly 6 Wrong tool selection 2 Tool issue only as per tools list
Established cutting parameters and
End User: Nil 1 Improper feed/Speed rate 2
program locked
20H)M10 'O' ring
detail 6 3
6 3
Coolant secondary filter provided &
Down stream operation: Nil 1 Coolant concentration 2 Before coolant top up, check coolant
concentricity through refractor meter
Establish tool change frequency and
Surface finish out of Assy: NA 1 Tool wear 2
Surface finish specify in Opn.std Inspection by inspector as per QCPC 6 108
spec
Customer:
6 Less Coolant flow 2 Failsafe alarm available in machine
Improper sealing
End User: Nil 1 Spindle speed / Feed rate high 3 Program locked
Pressure indicator to check the clamping
Clamping pressure more or less 2
pressure
Down stream operation:
1 Build up edge 2 Tool life monitoring provided
Nil
Established cutting parameters and
Assy: NA 1 Spindle speed / Feed rate high 3
program locked
II) Drill dia Oversize Customer: Fuel flow get affected 6 Burr entrapment into tool holder 2 Coolant spray in tool holder
End User: degradation of secondary
6 Wrong tool selection 2 Tool issue only as per tools list
function
Spindle runout 2 preventive maintenance
1) Drill ø3.00
6 3
Down stream operation:
1 Tool wear 2 Tool life monitoring provided
Nil
II) Drill dia undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list plug gauge check by operator 6 108
6 3
6 3
Down stream operation:
1 Resting pads not in same plane 2 Preventive maintanence
Nil
3) position X 1.25 Y Position
Assy: NA 1 Uneven clamping 3 preventive maintanence First off inspection 6 108
0.25 Out of spec
Customer: Component getting disturbed while Ensure proper clamping of component
6 2
Flow rate affected machining against resting as per OS
End User: Nil 1
6 3
Assy: Nil 1 Tool wear 3 Tool life monitoring provided Inspection by inspector through contour
I) Depth oversize tracer/ Also controlled by measuring 6 108
Customer: Fuel flow get affected 6 Ø5.1 depth
6 3
Down stream operation:
1 Build up edge 2 Tool life monitoring provided
Nil
Established cutting parameters and
Assy: NA 1 Spindle speed / Feed rate high 3
program locked
I) Drill dia oversize plug gauge check by operator 6 108
Customer: Fuel flow get affected 6 Burr entrapment into tool holder 2 Coolant spray in tool holder
6 3
Down stream operation:
1 Tool wear 2 Tool life monitoring provided
Nil
20 J) Ø5.1 pre
drill and Ø3 II) Drill dia undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list plug gauge check by operator 6 108
combination
Established cutting parameters and
Customer: Fuel flow get affected 6 Spindle speed / Feed rate high 3
program locked
6 3
l) depth Undersize Assy: Nil 1 Tool wear 3 Tool life monitoring provided FPG check by operator 6 108
4
Action Results
Occurrence
Detection
Occurrence
Severity
Responsibility
Detection
Class
Severity
Process Function Potential Failure Potential Cause(s) / Mechanism(s) Recommended
RPN
Opn Process Seq Potential Effects of Failure Current Process Controls prevention Current Process Controls detection and target
RPN
Requirements Mode. of Failure Actions* Actions taken
completion date
II) Depth oversize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list FPG check by operator 6 72
Customer: Fuel flow get affected 6 Wrong tool offset 2 Program locked
6 2
Down stream operation:
1 Build up edge 2 Tool life monitoring provided
Nil
Pressure indicator to check the clamping
Assy: NA 1 Clamping pressure more or less 2
3) Chamfer angle I) Chamfer angle more pressure
Inspection by inspector as per QCPC 6 72
118° or less
Customer: Improper assembly 6 Wrong tool selection 2 Tool issue only as per tools list
6 3
Down stream operation: Established cutting parameters and
1 Spindle speed / Feed rate high 3
Nil program locked
6 3
Down stream operation:
1 Build up edge 2 Tool life monitoring provided
Nil
20 K) Ø5 .6 Established cutting parameters and
Reaming Assy: NA 1 Spindle speed / Feed rate high 3
program locked
I) Dia oversize Air plug gauge check by operator 6 108
Customer: NRV will not assemble
6 Burr entrapment into tool holder 2 Coolant spray in tool holder
properly
End User: Nil 1 Wrong tool selection 2 Tool issue only as per tools list
1) Diameter
Spindle runout 2 preventive maintenance
Ø5.6 ± 0.05
6 3
Down stream operation:
1 Tool wear 2 Tool life monitoring provided
Nil
II) Dia undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Air plug gauge check by operator 6 108
Established cutting parameters and
Customer: NRV will not assemble 6 Spindle speed / Feed rate high 3
program locked
OPERATION NO. #30 LEFT HAND SIDE & RIGHT HAND SIDE -2nd SETUP
6 3
Down stream operation: Not able to
6 No machining Allowance 2 Insp. Done at casting stage
machine (non clearance)
Milling Height over size
Assy: NA 1 Wrong loading 3 Pokayoke provided 5 90
Gauge checked by operator
Customer:Assembly problem 6 Uneven clamping 3 Preventive maintanence
Established tool change frequency and
End User: Nil 1 Inserts worn out 2
specify in Opn.std
1) Milling Height wrong tool offset 2 Program locked
23.57±0.25,
37.43±0.25, Established tool change frequency and
Build up edge 3
52.30±0.30 specify in Opn.std
6 3
Down stream operation: Nil 1 Bend in the casting 3 Insp. Done at casting stage
Milling Height under Guide pin available in fixture to guide the
Assy: NA 1 Wrong loading 3 Gauge checked by operator 6 108
size part while loading
Customer: May affect / disturb at
6 Uneven clamping 3 preventive maintanence
assembly
End User: Nil 1 wrong tool offset 2 Program locked
6 3
Opn:30A) Milling
Down stream operation: Nil 1 Bend in the casting 3 Insp. Done at casting stage
6 3
II) dia undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list plug gauge check by operator 6 108
Customer: Solenoid valve will not Established cutting parameters and
6 Spindle speed / Feed rate high 3
assemble program locked
6 3
l) depth Undersize Assy: Nil 1 Tool wear 3 Tool life monitoring provided FPG check by operator 6 108
Customer: Fuel flow get affected 6 Wrong tool selection 2 Tool issue only as per tools list
II) Depth oversize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list FPG check by operator 6 72
Customer:Air & Fuel flow get affected 6 Wrong tool offset 2 Program locked
6 3
Down stream operation:
1 Build up edge 2 Tool life monitoring provided
Nil
I) Core hole dia Established cutting parameters and
Assy: NA 1 Spindle speed / Feed rate high 3 Core plug gauge check by operator 6 108
oversize program locked
Customer: Play in valve assembly 6 Wrong tool selection 2 Tool issue only as per tools list
5
Action Results
Occurrence
Detection
Occurrence
Severity
Responsibility
Detection
Class
Severity
Process Function Potential Failure Potential Cause(s) / Mechanism(s) Recommended
RPN
Opn Process Seq Potential Effects of Failure Current Process Controls prevention Current Process Controls detection and target
RPN
Requirements Mode. of Failure Actions* Actions taken
completion date
1 3
Down stream operation:
1 Build up edge 2 Tool life monitoring provided
Improper finish
30B) Ø14.8
counterbore , Ø13 Established cutting parameters and
Assy: NA 1 Spindle speed / Feed rate high 3
pre drill and Ø5.4 program locked Controlled by Ø5.9 Air gauge check by
I) drill dia oversize 6 18
drill operator
Customer: Nil 1 Wrong tool selection 2 Tool issue only as per tools list
(2 - places)
End User: Nil 1 Spindle runout 2 preventive maintenance
4) Pre drill diameter
Ø5.4
6 3
Down stream operation:
6 Tool wear 2 Tool life monitoring provided
Improper finish
Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Controlled by Ø5.9 Air gauge check by
II) drill dia undersize 6 108
operator
Established cutting parameters and
Customer: Nil 1 Spindle speed / Feed rate high 3
program locked
6 3
l) depth Undersize Assy: Nil 1 Tool wear 3 Tool life monitoring provided FPG check by operator 6 108
II) Depth oversize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list FPG check by operator 6 72
Customer:Air & Fuel flow get affected 6 Wrong tool offset 2 Program locked
6 3
l) depth Undersize Assy: Nil 1 Tool wear 3 Tool life monitoring provided Inspection by inspector as per QCPC 6 108
II) Depth oversize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Inspection by inspector as per QCPC 6 72
Customer: Valve will not assemble
6 Wrong tool offset 2 Program locked
properly
6 2
Down stream operation:
1 Build up edge 2 Tool life monitoring provided
Nil
7) Chamfer angle I) Chamfer angle more Pressure indicator to check the clamping
Assy: NA 1 Clamping pressure more or less 2 Inspection by inspector as per QCPC 6 72
45° or less pressure
Customer: Improper assembly 6 Wrong tool selection 2 Tool issue only as per tools list
II) Dia undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Air plug gauge check by operator 6 108
Customer: Assembly canot be carried Established cutting parameters and
6 Spindle speed / Feed rate high 3
out program locked
6 3
6 3
Coolant secondary filter provided &
Down stream operation: Nil 1 Coolant concentration 2 Before coolant top up, check coolant
concentricity through refractor meter
Establish tool change frequency and
Assy: NA 1 Tool wear 2
Surface finish out of specify in Opn.std
3) Surface finish Inspection by inspector as per QCPC
spec Customer:
6 Less Coolant flow 2 Failsafe alarm available in machine
Improper sealing
End User: Nil 1 Spindle speed / Feed rate high 3 Program locked
6 3
Down stream operation: Nil 1 Build up edge 3 Tool life monitoring provided
Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list
l) M14x1 6H thread
First off inspection 6 108
damage Coolant level indicator available and
Customer: 100% part scrapped 6 Coolant not flow 2
machine stops on low level
Pressure indicator to check the clamping
End User: Nil 1 Clamping pressure more or less 2
pressure
6 3
Down stream operation: Nil 1 Drill dia undersize 3 Tool life monitoring provided
1) M14x1 6H Thread
Establish tool change frequency and
size Assy: NA 1 Build up edge 3
ll) M14x1 6H thread Go specify in Opn.std
( 2 places ) SPG check by operator 6 108
not answering
Customer: Air & Fuel SOV not assemble 6 Coolant not flow 2 Flush coolant used to remove burr
End User: Nil 1 Wrong tool selection 2 Tool issue only as per tools list
6
Action Results
Occurrence
Detection
Occurrence
Severity
Responsibility
Detection
Class
Severity
Process Function Potential Failure Potential Cause(s) / Mechanism(s) Recommended
RPN
Opn Process Seq Potential Effects of Failure Current Process Controls prevention Current Process Controls detection and target
RPN
Requirements Mode. of Failure Actions* Actions taken
completion date
6 3
Customer: Air & Fuel SOV not assemble 6 Spindle runout 2 preventive maintenance
6 3
6 3
Down stream operation: Nil 1 Resting pads not in same plane 2 Preventive maintanence
3) Position Position
Assy: NA 1 Uneven clamping 3 preventive maintanence Receiver Gauge inspection by operator 5 90
0.6 wrt ABH Out of spec
Customer: Component getting disturbed while Ensure proper clamping of component
6 2
Cant able to assy the mating part machining against resting as per OS
6 3
Down stream operation:
1 Tool wear 2 Tool life monitoring provided
Nil
Established cutting parameters and
Assy: NA 1 Spindle speed / Feed rate high 3
program locked
I) Groove ID oversize Gauge check by operator 6 108
Customer: Seal will not assemble 6 Burr entrapment into tool holder 2 Coolant spray in tool holder
II) Groove ID undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Gauge check by operator 6 108
Established cutting parameters and
Customer: Seal will not assemble 6 Spindle speed / Feed rate high 3
program locked
6 3
Down stream operation:
1 Build up edge 2 Tool life monitoring provided
Nil
Established cutting parameters and
Assy: NA 1 Improper Spindle speed / Feed rate 3
I) Groove width program locked
Gauge check by operator 6 108
oversize
Customer: Seal will not assemble 6 Wrong tool selection 2 Tool issue only as per tools list
2)Groove width
6 3
Down stream operation:
1 Tool wear 2 Tool life monitoring provided
Nil
II) Groove width Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Gauge check by operator 6 108
undersize
Established cutting parameters and
Customer: Seal will not assemble 6 Improper Spindle speed / Feed rate 3
program locked
6 2
Down stream operation:
1 Build up edge 2 Tool life monitoring provided
Nil
30E) Grooving
I) Groove depth
Assy: NA 1 Wrong tool offset 2 Program locked Gauge check by operator 6 72
oversize
Customer: Seal will not assemble
6 Wrong tool selection 2 Tool issue only as per tools list
properly
End User: degradation of secondary
6
4)Groove depth function
1.2 - 0.15 6 2
Down stream operation:
1 Tool wear 2 Tool life monitoring provided
Nil
II) Groove depth Assy: NA 1 Wrong tool offset 2 Program locked Gauge check by operator 6 72
undersize
Customer: Seal will not assemble
6 Wrong tool selection 2 Tool issue only as per tools list
properly
6 2
Down stream operation:
1
Nil
Built-up edge 2 Tool life monitoring provided
I) Radius oversize Assy: NA 1 Inspection by inspector as per QCPC 6 72
II) Radius undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Inspection by inspector as per QCPC 6 72
6 3
6 3
Down stream operation:
1 Tool wear 2 Tool life monitoring provided
Nil
II) Drill dia undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Core plug gauge check by operator 6 108
Established cutting parameters and
Customer: Bolt will not enter 6 Spindle speed / Feed rate high 3
program locked
6 3
Down stream operation: Nil 1 Build up edge 3 Tool life monitoring provided
Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list
l) M8x1 6H thread
First off inspection 6 108
damage Coolant level indicator available and
Customer: 100% part scrapped 7 Coolant not flow 2
machine stops on low level
End User: Nil 1 Burr entrapment into tool holder 2 Coolant spray in tool holder
7
Action Results
Occurrence
Detection
Occurrence
Severity
Responsibility
Detection
Class
Severity
Process Function Potential Failure Potential Cause(s) / Mechanism(s) Recommended
RPN
Opn Process Seq Potential Effects of Failure Current Process Controls prevention Current Process Controls detection and target
RPN
Requirements Mode. of Failure Actions* Actions taken
completion date
6 3
Down stream operation: Nil 1 Drill dia undersize 3 Tool life monitoring provided
Establish tool change frequency and
Assy: NA 1 Build up edge 3
1) M4*0.7 Thread size specify in Opn.std
( 2 places ) ll) M4x0.7 6H thread Go
Customer: Screw not assemble 6 Coolant not flow 2 Flush coolant used to remove burr SPG check by operator 6 108
not answering
End User: Nil 1 Burr entrapment into tool holder 2 Coolant spray in tool holder
30G) M4*0.7
Tapping Wrong tool selection 2 Tool issue only as per tools list
(4 places)
Established cutting parameters and
Improper feed/Speed rate 2
program locked
6 3
Establish tool change frequency and
Down stream operation: Nil 1 Build up edge 3
specify in Opn.std
ll) M4x0.7 6H thread
Assy: NA 1 Tool runout 3 Preventive check (before tool issue) SPG check by operator 5 90
NOGO answering
Customer: Screw will shear due to cyclic
6 Burr entrapment into tool holder 2 Coolant spray in tool holder
load
End User: Nil 1 Spindle runout 2 preventive maintenance
6 3 5 90
6 3
Down stream operation: Nil 1 Build up edge 2 Tool life monitoring provided
6 3
Down stream operation:
1 Tool wear 2 Tool life monitoring provided
Nil
II) Drill dia undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Plug gauge check by operator 6 108
Established cutting parameters and
Customer: Part cannot assemble 6 Spindle speed / Feed rate high 3
program locked
30H) Ø3.1 drilling End User: Nil 1
6 3
l) depth Undersize Assy: Nil 1 Tool wear 3 Tool life monitoring provided FPG check by operator 6 108
II) Depth oversize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list FPG check by operator 6 108
6 3
Down stream operation:
1 Build up edge 2 Tool life monitoring provided
ø8.0 size not atcheived
Established cutting parameters and
Assy: NA 1 Spindle speed / Feed rate high 3
30I ) Ø4/7.40 1) Diameter I) Dia oversize / Under program locked
Air plug gauge check by operator 6 108
Drilling Ø4/7.40 size Customer: Assembly fitment will be
6 Burr entrapment into tool holder 2 Coolant spray in tool holder
losse
End User: Nil 1 Wrong tool selection 2 Tool issue only as per tools list
6 3
Down stream operation:
1 Build up edge 2 Tool life monitoring provided
Nil
Established cutting parameters and
Assy: NA 1 Spindle speed / Feed rate high 3
program locked
I) Dia oversize Air plug gauge check by operator 6 108
Customer: Assembly fitment will be
6 Burr entrapment into tool holder 2 Coolant spray in tool holder
losse
End User: Nil 1 Wrong tool selection 2 Tool issue only as per tools list
1) Diameter
Ø8 (-0.1/0.07)
Spindle runout 2 preventive maintenance
Down stream operation:
6 3
Nil
Assy: NA 1 Tool wear 2 Tool life monitoring provided
II) Dia undersize Air plug gauge check by operator 6 108
30I) Ø8 Reaming Customer: Assembly canot be carried
1 Wrong tool selection 2 Tool issue only as per tools list
out
Established cutting parameters and
End User: Nil 6 Spindle speed / Feed rate high 3
program locked
6 3
6 3
8
Action Results
Occurrence
Detection
Occurrence
Severity
Responsibility
Detection
Class
Severity
Process Function Potential Failure Potential Cause(s) / Mechanism(s) Recommended
RPN
Opn Process Seq Potential Effects of Failure Current Process Controls prevention Current Process Controls detection and target
RPN
Requirements Mode. of Failure Actions* Actions taken
completion date
6 3
Down stream operation:
1 Resting pads not in same plane 2 Preventive maintanence
Nil
3) position X 1.25 Y Position
Assy: NA 1 Uneven clamping 3 preventive maintanence First off inspection 6 108
0.25 Out of spec
Customer: Component getting disturbed while Ensure proper clamping of component
6 2
Flow rate affected machining against resting as per OS
End User: Nil 1
6 3
Down stream operation:
1 Build up edge 2 Tool life monitoring provided
Nil
Established cutting parameters and
Assy: NA 1 Spindle speed / Feed rate high 3
program locked
I) Drill dia oversize plug gauge check by operator 6 108
Customer: Fuel flow get affected 6 Burr entrapment into tool holder 2 Coolant spray in tool holder
6 3
Down stream operation:
1 Tool wear 2 Tool life monitoring provided
Nil
30K) Ø4 Drilling
II) Drill dia undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list plug gauge check by operator 6 108
Established cutting parameters and
Customer: Fuel flow get affected 6 Spindle speed / Feed rate high 3
program locked
6 3
6 3
Down stream operation:
4 Build up edge 2 Tool life monitoring provided
Nil
Established cutting parameters and
Assy: NA 1 Spindle speed / Feed rate high 3
program locked
I) Drill dia oversize Core plug gauge check by operator 6 108
Customer: Air flow get affected 6 Burr entrapment into tool holder 2 Coolant spray in tool holder
6 3
Down stream operation:
1 Tool wear 2 Tool life monitoring provided
Nil
II) Drill dia undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Core plug gauge check by operator 6 108
Established cutting parameters and
Customer: Air flow get affected 6 Spindle speed / Feed rate high 3
program locked
30L ) Ø5 Drilling End User: Nil 1
6 3
l) depth Undersize Assy: Nil 1 Tool wear 3 Tool life monitoring provided CPG check by operator 6 108
II) Depth oversize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Core plug gauge check by operator 6 72
Customer: Air flow get affected 6 Wrong tool offset 2 Program locked
6 3
Down stream operation:
1 Build up edge 2 Tool life monitoring provided
Nil
Established cutting parameters and
Assy: NA 1 Spindle speed / Feed rate high 3
program locked
I) Drill dia oversize plug gauge check by operator 6 108
Customer: Fuel flow get affected 6 Burr entrapment into tool holder 2 Coolant spray in tool holder
6 3
Down stream operation:
1 Tool wear 2 Tool life monitoring provided
Nil
II) Drill dia undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list plug gauge check by operator 6 108
Established cutting parameters and
Customer: Fuel flow get affected 6 Spindle speed / Feed rate high 3
program locked
End User: degradation of secondary
6
function
30M) Ø7.5 Drilling
6 2
Down stream operation:
1 Build up edge 2 Tool life monitoring provided
Nil
II) Depth undersize Assy: NA 1 Wrong tool offset 2 Program locked Gauge check by operator 6 72
Customer: Fuel flow get affected 6 Wrong tool selection 2 Tool issue only as per tools list
6 3
Down stream operation:
1 Tool wear 2 Tool life monitoring provided
Nil
II) Drill dia undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Core plug gauge check by operator 6 108
6 3
Down stream operation: Thread cannot
6 Wrong tool offset 2 Program locked
be formed properly
l) Depth Undersize Assy: Nil 1 Tool wear 3 Tool life monitoring provided Core plug gauge check by operator 6 108
9
Action Results
Occurrence
Detection
Occurrence
Severity
Responsibility
Detection
Class
Severity
Process Function Potential Failure Potential Cause(s) / Mechanism(s) Recommended
RPN
Opn Process Seq Potential Effects of Failure Current Process Controls prevention Current Process Controls detection and target
RPN
Requirements Mode. of Failure Actions* Actions taken
completion date
Customer: Fuel flow get affected 6 Wrong tool offset 2 Program locked
6 3
Down stream operation: Nil 1 Bend in the casting 3 Insp. Done at casting stage
Flatness
3) Flatness 0.1 Assy: NA 1 Uneven clamping 3 preventive maintanence First off Inspection 6 108
Out of spec
Customer: May affect / disturb at
6 Rest pads not in same plane 3 Fixture designed as per drawing
assembly
End User: Nil 1 Wrong tool offset 2 Program locked
6 3
l) depth Undersize Assy: Nil 1 Tool wear 3 Tool life monitoring provided Receiver gauge check by operator 6 108
Customer: Fuel flow get affected 6 Wrong tool offset 2 Program locked
6 3
Down stream operation: Nil 1 Build up edge 3 Tool life monitoring provided
Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list
l) M14x1.5 6H thread
SPG check by operator 6 108
damage Coolant level indicator available and
Customer: Filter not assemble 6 Coolant not flow 2
machine stops on low level
End User: Nil 1 Burr entrapment into tool holder 2 Coolant spray in tool holder
6 3
Down stream operation: Nil 1 Drill dia undersize 3 Tool life monitoring provided
Establish tool change frequency and
1) M14x1 .5 6H Assy: NA 1 Build up edge 3
specify in Opn.std
Thread size
ll) M14x1.5 6H thread
( 1 places ) Customer:Filter not assemble 6 Coolant not flow 2 Flush coolant used to remove burr SPG check by operator 6 108
Go not answering
End User: Nil 1 Burr entrapment into tool holder 2 Coolant spray in tool holder
6 3
6 3
Down stream operation:
1 Resting pads not in same plane 2 Preventive maintanence
2nd setup operation cannot be done
3) Position Position
Assy: NA 1 Uneven clamping 3 preventive maintanence Receiver Gauge inspection by operator 5 90
0.6 wrt GBA Out of spec
Customer: Component getting disturbed while Ensure proper clamping of component
6 2
Cant able to assy the mating part machining against resting as per OS
End User: Nil 1
6 3
Down stream operation: Nil 1 Build up edge 3 Tool life monitoring provided
Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list
15.80 + 0.1 intersection
SPG check by operator 6 108
dia oversize
Customer: O ring seat not properly 6 Spindle runout 2 Preventive maintanence
Down stream operation: Nil 1 Form tool intersection dia undersize 3 Tool life monitoring provided
30P) M14 O ring
detail 15.80 + 0.1 intersection Establish tool change frequency and
Assy: NA 1 Build up edge 3 SPG check by operator 6 108
dia undersize specify in Opn.std
Customer:O ring seat not properly 6 Wrong tool selection 2 Tool issue only as per tools list
Established cutting parameters and
End User: Nil 1 Improper feed/Speed rate 2
program locked
6 3
6 3
Coolant secondary filter provided &
Down stream operation: Nil 1 Coolant concentration 2 Before coolant top up, check coolant
concentricity through refractor meter
Establish tool change frequency and
Surface finish out of Assy: NA 1 Tool wear 2
specify in Opn.std Inspection by inspector as per QCPC 6 108
spec
Customer:
6 Less Coolant flow 2 Failsafe alarm available in machine
Improper sealing
End User: Nil 1 Spindle speed / Feed rate high 3 Program locked
II) Drill dia undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Core plug gauge check by operator 6 108
Established cutting parameters and
Customer: Bolt will not enter 6 Spindle speed / Feed rate high 3
program locked
6 3
6 3
10
Action Results
Occurrence
Detection
Occurrence
Severity
Responsibility
Detection
Class
Severity
Process Function Potential Failure Potential Cause(s) / Mechanism(s) Recommended
RPN
Opn Process Seq Potential Effects of Failure Current Process Controls prevention Current Process Controls detection and target
RPN
Requirements Mode. of Failure Actions* Actions taken
completion date
Down stream operation: Nil 1 Build up edge 3 Tool life monitoring provided
Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list
l) M10x1 6H thread
SPG check by operator 6 108
damage Coolant level indicator available and
Customer: Filter not assemble 6 Coolant not flow 2
machine stops on low level
End User: Nil 1 Burr entrapment into tool holder 2 Coolant spray in tool holder
6 3
Down stream operation: Nil 1 Drill dia undersize 3 Tool life monitoring provided
Establish tool change frequency and
1) M10x1 6H Thread Assy: NA 1 Build up edge 3
specify in Opn.std
size
ll) M10x1 6H thread Go
( 3 places ) Customer:Filter not assemble 6 Coolant not flow 2 Flush coolant used to remove burr SPG check by operator 6 108
not answering
End User: Nil 1 Burr entrapment into tool holder 2 Coolant spray in tool holder
6 3
6 3
Down stream operation:
1 Resting pads not in same plane 2 Preventive maintanence
3) Position 2nd setup operation cannot be done
Ø0.6 wrt JDA Position First off Inspection/ Interposition gauge
Assy: NA 1 Uneven clamping 3 preventive maintanence 6 108
Ø0.6 wrt FDA Out of spec check by operator
Ø0.6 wrt EAH Customer: Component getting disturbed while Ensure proper clamping of component
6 2
Cant able to assy the mating part machining against resting as per OS
End User: Nil 1
6 3
Coolant secondary filter provided &
Down stream operation: Nil 1 Coolant concentration 2
Before coolant top up, check coolant
Establish tool change frequency and
Surface finish out of Assy: NA 1 Tool wear 2
specify in Opn.std Inspection by inspector as per QCPC 6 108
spec Customer:
6 Less Coolant flow 2 Failsafe alarm available in machine
Improper sealing
End User: Nil 1 Spindle speed / Feed rate high 3 Program locked
Pressure indicator to check the clamping
1) Diameter Ø6.0 Clamping pressure more or less 2
pressure
6 3
Down stream operation:
1 Tool wear 2 Tool life monitoring provided
30S) Ø6.0Drilling Nil
II) Drill dia undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Core plug gauge check by operator 6 108
Established cutting parameters and
Customer: Bolt will not enter 6 Spindle speed / Feed rate high 3
program locked
End User: Nil 1
6 3
6 3
Down stream operation: Nil 1 Build up edge 3 Tool life monitoring provided
11.10 + 0.1 Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list
intersection dia SPG check by operator 6 108
oversize Customer: O ring seat not properly 6 Spindle runout 2 Preventive maintanence
Down stream operation: Nil 1 Form tool intersection dia undersize 3 Tool life monitoring provided
11.10 + 0.1
Establish tool change frequency and SPG check by operator 6 108
intersection dia Assy: NA 1 Build up edge 3
specify in Opn.std
undersize
Customer:O ring seat not properly 6 Wrong tool selection 2 Tool issue only as per tools list
Established cutting parameters and
End User: Nil 1 Improper feed/Speed rate 2
program locked
30U)M10 'O' ring
detail 6 3
6 3
Coolant secondary filter provided &
Down stream operation: Nil 1 Coolant concentration 2 Before coolant top up, check coolant
concentricity through refractor meter
Establish tool change frequency and
Surface finish out of Assy: NA 1 Tool wear 2
Surface finish specify in Opn.std Inspection by inspector as per QCPC 6 108
spec
Customer:
6 Less Coolant flow 2 Failsafe alarm available in machine
Improper sealing
End User: Nil 1 Spindle speed / Feed rate high 3 Program locked
Pressure indicator to check the clamping
Clamping pressure more or less 2
pressure
Down stream operation: Nil 1 Bend in the casting 3 Insp. Done at casting stage
Milling Height under Guide pin available in fixture to guide the
Assy: NA 1 Wrong loading 3 Gauge checked by operator 6 108
size part while loading
Customer: May affect / disturb at
6 Uneven clamping 3 preventive maintanence
assembly
End User: Nil 1 wrong tool offset 2 Program locked
1 3
Down stream operation:
1 Build up edge 2 Tool life monitoring provided
Nil
Established cutting parameters and
Assy: NA 1 Spindle speed / Feed rate high 3
program locked Inspection by inspector as per control
I) spot face dia oversize 6 18
plan
Customer: Nil 1 Burr entrapment into tool holder 2 Coolant spray in tool holder
End User: Nil 1 Wrong tool selection 2 Tool issue only as per tools list
6 3
Down stream operation:
1 Tool wear 2 Tool life monitoring provided
Nil
30W) Spot facing
11
Action Results
Occurrence
Detection
Occurrence
Severity
Responsibility
Detection
Class
Severity
Process Function Potential Failure Potential Cause(s) / Mechanism(s) Recommended
RPN
Opn Process Seq Potential Effects of Failure Current Process Controls prevention Current Process Controls detection and target
RPN
Requirements Mode. of Failure Actions* Actions taken
completion date
6 3
2) Flatness l) Flatness out of Assy: Nil 1 Tool wear 2 Tool life monitoring provided First off inspection 6 108
specification
Established cutting parameters and
Customer: Part cannot assemble 6 Spindle speed / Feed rate high 3
program locked
6 2
Down stream operation:
1 Build up edge 2 Tool life monitoring provided
Nil
II) Dia undersize Assy: NA 1 Wrong tool offset 2 Program locked Inspection by inspector as per QCPC 6 72
Customer: Seal will not enter Into the
6 Wrong tool selection 2 Tool issue only as per tools list
groove
6 2
Down stream operation:
1 Tool wear 2 Tool life monitoring provided
Nil
II) Depth undersize Assy: NA 1 Wrong tool offset 2 Program locked Receiver Gauge check by operator 6 72
Customer: May affect / disturb at
6 Wrong tool selection 2 Tool issue only as per tools list
assembly
6 3
End User: Nil 1 Wrong tool selection 2 Tool issue only as per tools list
1) Diameter
Spindle runout 2 preventive maintenance
Ø12 H9
6 3
Down stream operation:
1 Tool wear 2 Tool life monitoring provided
Nil
II) Dia undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Air plug gauge check by operator 6 108
Established cutting parameters and
Customer: Outlet valve will not assembe 6 Spindle speed / Feed rate high 3
program locked
6 3
Down stream operation:
1 Build up edge 2 Tool life monitoring provided
Nil
Established cutting parameters and
Assy: NA 1 Spindle speed / Feed rate high 3
program locked
I) Outer dia oversize Gap gauge check by operator 6 108
Customer: Part strengthen not good while
6 Burr entrapment into tool holder 2 Coolant spray in tool holder
running
End User: Nil 1 Wrong tool selection 2 Tool issue only as per tools list
6 3
Down stream operation:
1 Tool wear 2 Tool life monitoring provided
Nil
II) Outer dia undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Gap gauge check by operator 6 108
Established cutting parameters and
Customer: Leak during assembly 6 Spindle speed / Feed rate high 3
program locked
6 3
Down stream operation:
1 Build up edge 2 Tool life monitoring provided
Nil
Established cutting parameters and
Assy: NA 1 Spindle speed / Feed rate high 3
program locked
I) Outer dia oversize Gap gauge check by operator 6 108
Customer: Valve will not assemble 6 Burr entrapment into tool holder 2 Coolant spray in tool holder
End User: Nil 1 Wrong tool selection 2 Tool issue only as per tools list
6 3
Down stream operation:
1 Tool wear 2 Tool life monitoring provided
Nil
II) Outer dia undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Gap gauge check by operator 6 108
Established cutting parameters and
Customer: Leak during assembly 6 Spindle speed / Feed rate high 3
program locked
6 3
Down stream operation:
1 Build up edge 2 Tool life monitoring provided
Nil
Established cutting parameters and
Assy: NA 1 Improper Spindle speed / Feed rate 3
program locked
I) width oversize Thickness Gauge check by operator 6 108
Customer: Outlet valve will not assembe 6 Burr entrapment into tool holder 2 Coolant spray in tool holder
End User: Nil 1 Wrong tool selection 2 Tool issue only as per tools list
3) width
6 3
Down stream operation:
1 Tool wear 2 Tool life monitoring provided
Nil
II) width undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Thickness Gauge check by operator 6 108
12
Action Results
Occurrence
Detection
Occurrence
Severity
Responsibility
Detection
Class
Severity
Process Function Potential Failure Potential Cause(s) / Mechanism(s) Recommended
RPN
Opn Process Seq Potential Effects of Failure Current Process Controls prevention Current Process Controls detection and target
RPN
Requirements Mode. of Failure Actions* Actions taken
completion date
6 2
Down stream operation:
1 Tool wear 2 Tool life monitoring provided
Nil
5) Depth Assy: NA 1 Wrong tool offset 2 Program locked
II) Depth undersize Gap Gauge check by operator 6 72
8 Min
Customer: Seal will not assemble
6 Wrong tool selection 2 Tool issue only as per tools list
properly
6 2
Down stream operation:
1 Build up edge 2 Tool life monitoring provided
Nil
6 2
Down stream operation:
1 Build up edge 2 Tool life monitoring provided
Nil
7) Chamfer angle I) Chamfer angle more Pressure indicator to check the clamping
Assy: NA 1 Clamping pressure more or less 2 Inspection by inspector as per QCPC 6 72
ii)45° or less pressure
Customer: Seal will not assemble
6 Wrong tool selection 2 Tool issue only as per tools list
properly
End User: degradation of secondary
6
function
Functional Characteristic
Down stream operation: Nil 1 Damage due to deburring 3 Trained Operator 200% Visual inspection 7 147
Handling damage while loading the Single setup and provided proper material
No damage Damage Assy: Nil 1 2 100% Visual inspection 8 112
machine handling in machine
Customer :
7 Clamping pressure high 2 Preventive maintenance Process audit 8 112
100% parts may have to be scrapped
7 2 Firstoff inspection 5 70
Down stream operation :
1 Clamping pressure less/high 2 Preventive maintenance Process audit 8 112
Nil
No Tool mark Tool mark Customer : Establish tool change frequency and
7 Tool wear 2 200% Visual inspection 7 98
100% parts may have to be scrapped specify in Opn.std
Assy : Establish tool change frequency and
1 Build up edge 2 200% Visual inspection 7 98
NA specify in Opn.std
End user :
1 Jack supporting pressure low/high 2 None Preventive check and process audits 7 98
Nil
6 3 Firstoff inspection 5 90
30Y) Functional
Characteristic Down stream operation :
100% parts may have to be reworked 6 Coolant concentration not ok 3 None Checked once per day 6 108
offline
Free from Loose Customer :
Loose Burrs Optimize coolant flow during machining
Burrs 100% of production run may have to be 6 Coolant not flow 2 Process audit 7 84
scrapped. trials
Assy :
1
NA
End user :
1
Nil
6 2
Down stream operation :
Nil 1 Tool wear 2 Tool life Monitoring established
6 2 Firstoff inspection 5 60
As per established Air pressure indicated Monitoring the right pressure thru pressure
Down stream operation: Nil 1 Insufficient Air pressure 2 6 72
in OS gauge
Air cleaning of parts Free from presence of
40) Deburring & Customer:
to be free from burrs or coolant 6
Air cleaning a) Fails at performance testing Untrained operator 2 Trained operator Process audit 7 84
sharpe edge, burrs particles inside the
process b) Leads to White rust formation
and coolant particles component
Air pressure gauge level unknown to
Assy: Nil 1 2 Established air pressure used in line Process audit 7 84
operator
6 3
As per the given Down stream operation: Nil 1 Contaminated water (PH) 3 Water change frequency monitoring
50) Washing Cleanliness standard
16599 Firstoff inspection 6 108
ii)Contamination due to Assy: Nil 1 Oil skimmer not functioning 2 Preventive maintanence
Oil/ Dirt/ Coolant
Customer:
a) Affects part performanc after 6 Water not good 3 Water change frequency monitoring
assembling the part
5 3
13
Action Results
Occurrence
Detection
Occurrence
Severity
Responsibility
Detection
Class
Severity
Process Function Potential Failure Potential Cause(s) / Mechanism(s) Recommended
RPN
Opn Process Seq Potential Effects of Failure Current Process Controls prevention Current Process Controls detection and target
RPN
Requirements Mode. of Failure Actions* Actions taken
completion date
Assy: Nil 1 Water temperature low 3 Preventive maintanence 100% check for white rust by final
iii) White rust 6 90
Customer: inspector
5 Contaminated water (PH) 3 Water change frequency monitoring
a)Poor outside side look of the part
Water change frequency not
End User: Nil 1 3 None
monitoring
Component kept at washing station Timing sensor available/ Heater available
2
for long to remove moisture
OPERATION NO. #60 Impregnation
6 3
Down stream operation: Leak due to
1 Resin concentration 3 As per established in OS
cavity unfill
Free from IMP Customer:
solution blockage / IMP solution blockage / a) Leak may occur 6 Untrained operator 3 Trained operator 100% checked by operator,
60) Impregnation Unwash / IMP Unwash / IMP b) Leads to White rust formation 100% IMP punch verified by final 6 108
concentration not concentration not good Clear identification to be followed inspector
good a) Punch mark provided on Ok parts by
Assy: Nil 1 Leak testing operation missing 3
machine before declamping
b) 200% Visual inspection
End User: Nil 1 Impregnation missing 3 Nil
6 3
6 3
As per the given Down stream operation: Nil 1 Contaminated water (PH) 3 Water change frequency monitoring
80) Washing Cleanliness standard
16599 Firstoff inspection 6 108
ii)Contamination due to Assy: Nil 1 Oil skimmer not functioning 2 Preventive maintanence
Oil/ Dirt/ Coolant
Customer:
a) Affects part performanc after 6 Water not good 3 Water change frequency monitoring
assembling the part
5 3
Assy: Nil 1 Water temperature low 3 Preventive maintanence 100% check for white rust by final
iii) White rust 6 90
Customer: inspector
5 Contaminated water (PH) 3 Water change frequency monitoring
a)Poor outside side look of the part
Water change frequency not
End User: Nil 1 3 None
monitoring
Component kept at washing station Timing sensor available/ Heater available
2
for long to remove moisture
OPERATION NO. #90 Air Cleaning
5 3
Down stream operation :
5 Air cleaning Pressure 3 Preventive maintanence
Nil
Heater time established, Timing sensor
90) Air Cleaning Air cleaning Free from moisture Assy : NA 1 Cleaning temperature 2 100% checked by final inspection 6 90
available
Customer : Nil 1
5 3
Down stream operation :
100% of production run may have to be 5 Heater Temperature not in spec 3 Preventive maintanence
reworked in station.
100) Drying Drying Free from moisture Heater time established, Timing sensor 100% checked by final inspection 6 90
Assy : NA 1 Heater Cycle time less 2
available
Customer : Nil 1
5 3
5 3
1) Parts free from
1) No damage while Operator not aware of identifying the a) OJT for final inspectors
visual defects like Down stream operation: Nil 1 3
transporting visual defects b) Operator traceability code on the part
damages, white rust
2)Parts getting mixed 100% check by final inspection 6 90
120) Packing 2) Free from part mixup Assy: Nil 1 Part getting mixed up 3 Only one variant running at that time
up
Customer:
5
a) Fails performance testing
End User: Nil 1
*Priorites for determining recommended action: 1) Severity ≥ 8 ; (OR) 2) Detection > 6 ; (OR) 3) RPN ≥ 125
F/PED/04-M; Rev No.1; Dated: 25.02.2010
14