06) - Fmea For 11190722 - D

INDO SHELL CAST PVT LTD Refrence no : ISC-TS-CFT-FMEA-D11
UNIT-II, FAILURE MODE EFFECTIVE ANALYSIS Report no : CP/07/SRD-01

COIMBATORE,
INDIA. Key date : 22.02.2018 FMEA DATE (Orig ) : 22.02.2018
Model/Vehicle : M/S DANFOSS POWER SOLUTIONS (US) COMPANY. Part description : CAT SWL INLET MACHINED Revsion Date : 15.05.2019
Core team : S.Selvam, S.Anandan, P.M.Peter, R.Siva Kumar, O.Ganesan, N.Dinesh Kumar, A.Sridhar,
Part no : 11190722 / D Revsion No. : 04
P.Karthickraja, Arun Kumar, Ranjith Kumar, J.Kumaravel & Ranganathan.
Current Process Action Results
Detection
severity
Responsibility &
class
Occurrence
RPN
Process Potential Potential Cause(s)/Mechanism(s) of
Layout No Requirements Potential effect(s) of failure Recommended Action(s) Target
Function Failure Mode Failures
Controls Prevention Controls Detection Completion Date Action Taken Sev Occ Det RPN
OPERATION NO :- 10 RAW MATERIAL FROM FOUNDRY TO MACHINE SHOP

1). Work instruction (ISC-II-MS-WI- 022) displayed
Next Operation 1) Parts not stacking properly 1)Inward /Receiving inspection
at shop floor
Part rejected 2) Dedicated bins not available 2). Training Provided for material handling Inward /Receiving inspection
Subsequent Operation
3) Severity of the problem not explained to the 100% Visually checked wheather it is covered
Un known of seriousness On the job training
operators properly
PARTS DAMAGED 4 3 7 84
Assembly
No Effect
End user
No Effect
CASTING WITHOUT VISUAL
DEFECTS
Next Operation
Parts need to be rework 1). Parts stored in open place 1). Dedicated layout provided
Subsequent Operation 2). Parts not dipped in oil 2). Oil dipping process included in process flow
10. Problem in semifinish operation 3). Parts are transferred by roofless vechile 3). Covered vechile or Tarpaulin used
RUST 100 % Visual inspection carried out at inward
TRANSPORTATION NA 2 3 8 48
APPEARANCE inspection
& STORAGE Assembly
No Effect
End user
No Effect
Next Operation
Quantity excess or shortage while machining 1). Quantity excess or shortage while machining Proper counting with trained persons
No Effect
QUANTITY AS PER MENTIONED IN IMPROPER
3 3 100% Visual inspection with delivery chalan 8 72
DELIVERY CHALAN COUNTING
Assembly
No Effect
End user
No Effect
OPERATION NO :- 20 RAW MATERIAL INSPECTION

Next Operation
Causes poor machining
20. PARAMETERS Causes poor

CASTING WITHOUT DEFECTS & machining in further process 1). Improper inspection, 1). Proper inspection, Inspection as per SSIP level 1 with appropriate
RAW MATERIAL NA OUT OF 4 3 7 84
PRODUCT SPECIFICATIONS 2). Ineffecient training to the inspector. 2). Effective training to the operator. measuring instruments Incoming inspectiopn
INSPECTION SPECIFICATIONS Assembly
No Effect
End user
No Effect
OPERATION NO :- 30 RAW MATERIAL STORAGE

Next Operation
Part rejected
30. Problem in next operation

1)OPL /Work instruction displayed at shop floor (
RAW MATERIAL NA PARTS WITHOUT DAMAGE PARTS DAMAGED 4 1) Improper stacking 3 100% Visual inspection 7 84
ISC-MS-SRDAN-02-PM )
STORAGE Assembly
No Effect
End user
No Effect
PAGE NO- 1 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN
OPERATION NO :- 10 Next Operation

RAW MATERIAL FROM FOUNDRY TO MACHINE SHOP
Time delayed due to sorting of 100%
30. Time delayed due to sorting of 100%
RAW MATERIAL NA PARTS WITHOUT MIXUP PARTS MIXED UP 4 zig-zag material flow dedicted layout 3 Inward inspection 7 84
STORAGE Assembly
No Effect
End user
No Effect
OPERATION NO :- 40 RAW MATERIAL TRANSPORTATION FROM STORAGE AREA TO MACHINE SHOP

1). Work instruction (ISC-II-MS-WI- 022) displayed
Next Operation 1) Parts not stacking properly 1)Inward /Receiving inspection
at shop floor
Part rejected 2) Dedicated bins not available 2). Training Provided for material handling Inward /Receiving inspection
3) Severity of the problem not explained to the 100% Visually checked wheather it is covered
PARTS DAMAGED Un known of seriousness 4 operators
On the job training 3 properly 7 84
Assembly
No Effect
40.
RAW MATERIAL End user
TRANSPORTATION CASTING WITHOUT VISUAL No Effect
NA
FROM STORAGE DEFECTS
AREA TO MACHINE Next Operation
SHOP Parts need to be rework 1). Parts stored in open place 1). Dedicated layout provided
Subsequent Operation 2). Parts not dipped in oil 2). Oil dipping process included in process flow
RUST Problem in semifinish operation 3). Parts are transferred by roofless vechile 3). Covered vechile or Tarpaulin used 100 % Visual inspection carried out at inward
3 3 8 72
APPEARANCE Assembly inspection
No Effect
End user
No Effect
OPERATION NO :- 50 PRE MACHINING - 1 ( DATUM "E" OPPOSITE SIDE )

Next Operation 1). Wrong Tool Offset 1). Dead stopper on lathe machine slide
Master program verification, job set up and As per
Stock minimized at next operation / Unwash Sampling Plan (ISC-II-TS-QCD-SSIP-D02)
2). Improper M/C Setup 2). Proper checked JSIR
observed at face
periodic inspection with 2D Height Gauge
Subsequent Operation 3). Tool built up edge 3). Alarm & lock in machine for tool life excess
4). Preventive maintainance Plan Preventive maintainance Record (ISCII-TS-MTC-
DISTANCE UNDER No Effect 4). Play in cross slide
5 ( ISCII-TS-MTC-PMP/C-R04 ) 3 PMP-R05) with CMK study 5 75
SIZE
Assembly
No Effect
End User
CORE HOLE DISTANCE FOR No Effect
--- 32.00±0.50 STOCK
( 32.20(-0.00 to +0.10)mm ) Next Operation 1). Wrong Tool Offset 1). Dead stopper on lathe machine slide
Load for the next process will be high and it may Sampling Plan (ISC-II-TS-QCD-SSIP-D02)
lead to lower the tool life periodic inspection with 2D Height Gauge
Subsequent Operation 3). Tool wear 3). Alarm & lock in machine for tool life excess
DISTANCE OVER 4). Preventive maintainance Plan Preventive maintainance Record (ISCII-TS-MTC-
No Effect 4 4). Play in cross slide 3 6 72
SIZE ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
Assembly
No Effect
End User
50.
PRE MACHINING - 1 No Effect
( DATUM "E"
OPPOSITE SIDE ) Next Operation 1). Wrong Tool Offset 1). Dead stopper on lathe machine slide Master program verification, job set up and As per
2). Improper M/C Setup 2). Proper checked JSIR periodic inspection with 2D Height Gauge (or)
observed at face
Digital Vernier Caliper
THICKNESS 4). Preventive maintainance Plan Preventive maintainance Record (ISCII-TS-MTC-
UNDER SIZE ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
Assembly
No Effect
End User
TOTAL THICKNESS FOR No Effect
--- 67.00±0.50 STOCK
( 69.20(-0.00 to +0.10)mm ) Next Operation 1). Wrong Tool Offset 1). Dead stopper on lathe machine slide Master program verification, job set up and As per
2). Improper M/C Setup 2). Proper checked JSIR periodic inspection with 2D Height Gauge (or)
lead to lower the tool life
THICKNESS 4). Preventive maintainance Plan Preventive maintainance Record (ISCII-TS-MTC-
OVER SIZE ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
Assembly
No Effect
End User
No Effect
PAGE NO- 2 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN
10 PRE
OPERATION NO :- 60 RAWMACHINING
MATERIAL FROM FOUNDRY
- 2 ( DATUM TO MACHINE
"E" SIDE ) SHOP
Next Operation 1). Tool worn out 1) tool freq. mentioned TMC
Taper of drills , coordinates erros, 2). Improper M/C Setup 2). Proper checked JSIR Sampling Plan (ISC-II-TS-QCD-SSIP-D02)
periodic inspection with Height Gauge with dial
Subsequent Operation 3). Tool built up edge / wear 3). Alarm & lock in machine for tool life excess
PARALLELISM ON DATUM 'E'
OPPOSITE FACE No Effect 4). Play in cross slide
OUT OF ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
--- 6 3 5 90
SPECIFICATION
Assembly
( f | 0.30 | E )
No Effect
End User
No Effect
Next Operation 1). Wrong Tool Offset 1). Dead stopper on lathe machine slide
observed at face periodic inspection with 2D Height Gauge (or)
60. 4). Preventive maintainance Plan Preventive maintainance Record (ISCII-TS-MTC-

THICKNESS No Effect 4). Play in cross slide
PRE MACHINING - 2 5 ( ISCII-TS-MTC-PMP/C-R04 ) 3 PMP-R05) with CMK study 5 75
UNDER SIZE
( DATUM "E" SIDE ) Assembly
No Effect
End User
TOTAL THICKNESS FOR No Effect

--- 67.00±0.50 STOCK
( 67.40(-0.00 to +0.10)mm ) Next Operation 1). Wrong Tool Offset 1). Dead stopper on lathe machine slide
lead to lower the tool life periodic inspection with 2D Height Gauge (or)
THICKNESS OVER No Effect 4). Play in cross slide
( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
4 3 6 72
SIZE
Assembly
No Effect
End User
No Effect
OPERATION NO :- 70 RAW MATERIAL INSPECTION

Next Operation
Causes poor machining
70.
PARAMETERS Causes poor machining in further process
PRE MACHINING CASTING WITHOUT DEFECTS & 1). Improper inspection, 1). Proper inspection, Inspection as per SSIP level 1 with appropriate
NA OUT OF 4 3 7 84
INWARD PRODUCT SPECIFICATIONS 2). Ineffecient training to the inspector. 2). Effective training to the operator. measuring instruments Incoming inspectiopn
SPECIFICATIONS Assembly
INSPECTION
No Effect
End user
No Effect
OPERATION NO :- 80 SURFACE GRINDING-1 ( DATUM "E" OPPOSITE SIDE )

Next Operation 1). Improper M/C Setup 1). Proper checked JSIR Master program verification at Job set up and 25
jobs once periodic inspection with Surface
No Effect 2). Grinding wheel worn out 2). Alarm & lock in machine for tool life excess Roughness Tester
SURFACE FINISH ON DATUM 'E' 3). Preventive maintainance Plan

Subsequent Operation 3). M/C Bed Flatness More Poor awarness Preventive maintainance Record (ISCII-TS-MTC-
OPPOSITE FACE ( ISCII-TS-MTC-PMP/C-R04 )
OUT OF 4). Preventive maintainance Plan PMP-R05) with CMK study
75 Part get rejected at final inspection 8 4). Play in cross slide 2 6 96
SPECIFICATION ( ISCII-TS-MTC-PMP/C-R04 )
Ra 2.50
( 2X Rz 16 ) Assembly
Performance failure
80. End User

SURFACE Reduced Performance
GRINDING-1
( DATUM "E" Next Operation 1). Improper M/C Setup 1). Proper checked JSIR Master program verification at Job set up and 25
OPPOSITE SIDE ) jobs once periodic inspection with Surface
SURFACE FINISH ON DATUM 'E' 3). Preventive maintainance Plan

Subsequent Operation 3). M/C Bed Flatness More Poor awarness
OPPOSITE FACE ( ISCII-TS-MTC-PMP/C-R04 ) Preventive maintainance Record (ISCII-TS-MTC-
OUT OF PMP-R05) with CMK study
79 8 4). Preventive maintainance Plan 2 6 96
SPECIFICATION Part get rejected at final inspection 4). Play in cross slide
Ra 2.50 ( ISCII-TS-MTC-PMP/C-R04 )
( 2X Rz 16 ) Assembly
Performance failure
End User
Reduced Performance
PAGE NO- 3 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

jobs once periodic inspection with CMM & 4 No"s
No Effect 2). Grinding wheel worn out 2). Alarm & lock in machine for tool life excess Per Shift Cpu Chart Inspection with CMM
3). Preventive maintainance Plan

FLATNESS ON DATUM 'E' ( ISCII-TS-MTC-PMP/C-R04 ) Preventive maintainance Record (ISCII-TS-MTC-
OPPOSITE FACE 4). Preventive maintainance Plan PMP-R05) with CMK study
OUT OF Part get rejected at final inspection 4). Play in cross slide
77 8 ( ISCII-TS-MTC-PMP/C-R04 ) 2 6 96
SPECIFICATION
(2X c | 0.035 ) Assembly
Performance failure
End User
Reduced Performance

FLATNESS ON DATUM 'E' ( ISCII-TS-MTC-PMP/C-R04 ) Preventive maintainance Record (ISCII-TS-MTC-
OPPOSITE FACE 4). Preventive maintainance Plan PMP-R05) with CMK study
OUT OF Part get rejected at final inspection 4). Play in cross slide
SPECIFICATION
(2X c | 0.035 ) Assembly
Performance failure
End User
80.
SURFACE Reduced Performance
GRINDING-1 1). Key lock for un autorised access & program
( DATUM "E" Next Operation 1). Wrong offset
control for parameters
OPPOSITE SIDE ) Master program verification at Job set up and 5
Stock minimized at next operation / Unwash jobs once periodic inspection with 2D Height
observed at face Gauge
Subsequent Operation 2). Grinding wheel wear out 3). Alarm & lock in machine for tool life excess
THICKNESS 4). Preventive maintainance Plan

No Effect 5 4). M/C Bed Flatness More Poor awarness 3 5 75
( ISCII-TS-MTC-PMP/C-R04 ) Preventive maintainance Record (ISCII-TS-MTC-
UNDER SIZE
5). Preventive maintainance Plan PMP-R05) with CMK study
Assembly 5). Play in cross slide
( ISCII-TS-MTC-PMP/C-R04 )
No Effect
End User
TOTAL THICKNESS FOR
--- 67.00±0.50 STOCK No Effect
( 4 X 67.15±0.06mm ) 1). Key lock for un autorised access & program
Next Operation 1). Wrong offset
Master program verification at Job set up and 5
Load for the next process will be high and it may jobs once periodic inspection with 2D Height
lead to lower the tool life Gauge
Subsequent Operation 3). Grinding wheel worn out 3). Alarm & lock in machine for tool life excess
THICKNESS OVER 4). Preventive maintainance Plan
No Effect 4 4). M/C Bed Flatness More Poor awarness 3 6 72
SIZE ( ISCII-TS-MTC-PMP/C-R04 ) Preventive maintainance Record (ISCII-TS-MTC-
No Effect
End User
No Effect
OPERATION NO :- 90 SURFACE GRINDING-2 ( DATUM "E" -SIDE )

1). Key lock for un autorised access & program
control for parameters Master program verification at Job set up and 5
jobs once periodic inspection with 2D Height
No Effect 2). Improper M/C Setup 2). Proper checked JSIR
Gauge
DISTANCE UNDER Part get rejected at final inspection 4). Preventive maintainance Plan
7 4). M/C Bed Flatness More Poor awarness 3 Preventive maintainance Record (ISCII-TS-MTC- 4 84
SIZE ( ISCII-TS-MTC-PMP/C-R04 )
Fitment problem
End User
90.
SURFACE No Effect
TOTAL THICKNESS
GRINDING-2 102 A 1). Key lock for un autorised access & program
( 67.00±0.50mm ) Next Operation 1). Wrong offset
( DATUM "E" -SIDE control for parameters Master program verification at Job set up and 5
) jobs once periodic inspection with 2D Height
No Effect 2). Improper M/C Setup 2). Proper checked JSIR
Gauge
DISTANCE OVER Part get reject/rework at final inspection 4). M/C Bed Flatness More Poor awarness
6 ( ISCII-TS-MTC-PMP/C-R04 ) 3 Preventive maintainance Record (ISCII-TS-MTC- 5 90
SIZE
Fitment problem
End User
No Effect
PAGE NO- 4 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN
OPERATION NO :- 10 RAW MATERIAL FROM FOUNDRY TO MACHINE SHOP 1). Key lock for un autorised access & program
No Effect 2). Improper M/C Setup 2). Proper checked JSIR jobs once periodic inspection with CMM (or) 2D
Height Gauge
DISTANCE UNDER 4). Preventive maintainance Plan

Part get rejected at final inspection 8 4). M/C Bed Flatness More Poor awarness 3 5 120
Fitment problem
End User
CORE HOLE DISTANCE No Effect
57
( 32.00±0.50mm )
1). Key lock for un autorised access & program
control for parameters Master program verification at Job set up and 5
No Effect 2). Improper M/C Setup 2). Proper checked JSIR jobs once periodic inspection with CMM (or) 2D
Height Gauge
Part get reject/rework at final inspection 4). M/C Bed Flatness More Poor awarness
DISTANCE OVER ( ISCII-TS-MTC-PMP/C-R04 ) Preventive maintainance Record (ISCII-TS-MTC-
8 3 6 144
SIZE 5). Preventive maintainance Plan PMP-R05) with CMK study
Fitment problem
End User
No Effect
jobs once periodic inspection with Surface

SURFACE FINISH ON DATUM 'E' ( ISCII-TS-MTC-PMP/C-R04 ) Preventive maintainance Record (ISCII-TS-MTC-
FACE OUT OF 4). Preventive maintainance Plan PMP-R05) with CMK study
Ra 2.50
( Rz 16 ) Assembly
Performance failure
90.
SURFACE End User
GRINDING-2
( DATUM "E" -SIDE Reduced Performance
) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR Master program verification at Job set up and 25

FLATNESS ON DATUM 'E' FACE
OUT OF 4). Preventive maintainance Plan PMP-R05) with CMK study
( c | 0.035 )
Assembly
Performance failure
End User
Reduced Performance
No Effect 2). Grinding wheel worn out 2). Alarm & lock in machine for tool life excess Gauge
OPPOSITE FACE Part get rejected at final inspection 4). Play in cross slide
OUT OF ( ISCII-TS-MTC-PMP/C-R04 )
76 6 3 5 90
SPECIFICATION
(2X |
f | 0.50 E ) Assembly
Performance failure
End User
Reduced Performance
No Effect 2). Grinding wheel worn out 2). Alarm & lock in machine for tool life excess Gauge
OPPOSITE FACE Part get rejected at final inspection 4). Play in cross slide
80 6 3 5 90
SPECIFICATION
(2X |
f | 0.50 E ) Assembly
Performance failure
End User
Reduced Performance
PAGE NO- 5 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN
OPERATION NO :- 10
100 -RAW MATERIAL
( DATUM FROM FOUNDRY
"E" OPPOSITE TO MACHINE
SIDE ) SPOT SHOP FORMING, DRILLING, TAPPING & CHAMFERING
FACING, PORT
1). Product placed in wrong position while 1). Proper training provided for clamping
Next Operation 100% Visual Inspection with Fixture set up
clamping Operation standard ( OP/08/DFS-08 ).
1). Lead to tool breakage in current operation
2). Proper training provided for clamping
2). Can not achive the product specification in 2). Clamping tight variation 100% proper tighted (15 to 25 Nm ) with allen Key
Operation standard ( OP/08/DFS-08 ).
current operation
100.(01) Subsequent Operation

IMPROPER
CLAMP THE JOB IN --- PROPER CLAMPING Part get rejected at final inspection 7 2 6 84
CLAMPING
FIXTURE
Assembly
No Effect
End User
No Effect
Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
Can not achive the dimension Ø11.00(+0.001 to
+0.011)mm in 100.4th process and get rejected 2). Tool built up edge 2). Alarm & lock in machine for tool life excess Tool verification as per tool package sheet before
at 100.4th process part setting
3). Key lock for un authorised access & Program
Subsequent Operation 3). Wrong Tool selection
control for parameter
DIAMETER OVER 4). Preventive maintainance Plan
Part get rejected at final inspection 5 4). Tool worn out 2 5 50
Assembly 5). Machine axis variation (machine wear)
No Effect
HOLE DIAMETER ON Ø11.00(+0.001
End User
to +0.011) STOCK
---
No Effect
( Ø10.70±0.10mm )
Load for the 100.4th process will be high and it
2). Tool wear out 2). Alarm & lock in machine for tool life excess
may lead to lower the tool life Tool verification as per tool package sheet before
3). Key lock for un authorised access & Program part setting
DIAMETER
Possibility for subsequent tool broken 6 2 4 48
UNDER SIZE
Assembly
No Effect
End User
No Effect
Can not achive the dimension 35.00±0.20 mm in
100.4th process and get rejected at 100.4th 2). Tool built up edge 2). Alarm & lock in machine for tool life excess
process
3). Key lock for un authorised access & Program Master program verification
100.(02) Subsequent Operation 3). Wrong Tool selection
Ø10.70MM DRILLING 4). Key lock for un authorised access & Program
FOR Ø11.00 DEPTH OVER Part get rejected at final inspection 4). Wrong Tool offset
6 control for parameter 3 4 72
ROUGHING - 1 SIZE
PLACE Assembly 5). Wrong work offset
( DATUM "E"
OPPOSITE SIDE ) Fitment problem not mating with mating part
End User
HOLE DEPTH ON Ø10.70 No Effect

---
( 35.00±0.20mm )

may lead to lower the tool life
Part get rejected at final inspection 4). Wrong Tool offset
DEPTH UNDER control for parameter
7 3 4 84
SIZE 5). Key lock for un authorised access & Program
Assembly 5). Wrong work offset
No Effect
End User
No Effect
Next Operation 1). Program change
control for parameter Master program verification
Possibility for combination reamer broken 2). Wrong work offset
Subsequent Operation 3). Machine axis variation (machine wear)
POSITION ON Ø10.70 ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
OUT OF
--- Part get rejected at final inspection 5 2 5 50
SPECIFICATION
( j | Ø0.30 | E | F-G | G )
Assembly
Fitment problem not mating with mating part
End User
No Effect
PAGE NO- 6 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

100.(02) Possibility for combination reamer broken 2). Wrong work offset
Ø10.70MM DRILLING 3). Preventive maintainance Plan Preventive maintainance Record (ISCII-TS-MTC-
CENTER DISTANCE ON Ø10.70 Subsequent Operation 3). Machine axis variation (machine wear)
FOR Ø11.00 ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
OUT OF
ROUGHING - 1 --- Part get rejected at final inspection 5 2 4 40
( 15.40±0.15mm ), SPECIFICATION
PLACE
( 11.00±0.15mm ). Assembly
( DATUM "E"
End User
No Effect
No Effect 2). Tool built up edge 2). Alarm & lock in machine for tool life excess Nos once periodic inspection with Groove vernier
3). Key lock for un authorised access & Program caliper (or) CMM
Loose Fitment problem not mating with mating
part
End User
HOLE DIAMETER
183 Q No Effect
( Ø12.20±0.20mm )
No Effect 2). Tool wear out 2). Alarm & lock in machine for tool life excess Master program verification at Job set up and 5
Nos once periodic inspection with Groove vernier
Subsequent Operation 3). Wrong Tool selection caliper (or) CMM
DIAMETER
Part get rejected at final inspection 7 3 4 84
UNDER SIZE
Assembly
Tight Fitment problem not mating with mating part
End User
No Effect
No Effect 2). Tool built up edge 2). Alarm & lock in machine for tool life excess
Subsequent Operation 3). Wrong Tool selection Nos once periodic inspection with Digital Height
Gauge
DEPTH OVER 4). Key lock for un authorised access & Program
Part get rejected at final inspection 6 4). Wrong Tool offset 3 4 72
SIZE control for parameter
100.(03) End User
Ø12.20MM DRILLING
- 1 PLACE 183 D
( DATUM "E" ( 13.00±0.20mm )
OPPOSITE SIDE )
No Effect 2). Tool wear out 2). Alarm & lock in machine for tool life excess
Gauge
DEPTH UNDER 4). Key lock for un authorised access & Program
End User
No Effect
control for parameter Master program verification at Job set up and
2). Key lock for un authorised access & Program Shift once periodic inspection with CMM
No Effect 2). Wrong work offset
POSITION ON Ø12.20 Subsequent Operation 3). Machine axis variation (machine wear)
184 Part get rejected at final inspection 7 2 6 84
SPECIFICATION
( j | Ø0.30 | E | F | G )
Assembly
End User
No Effect
control for parameter Master program verification at Job set up
2). Key lock for un authorised access & Program inspection with CMM
CENTER DISTANCE ON Ø12.20 3). Preventive maintainance Plan Preventive maintainance Record (ISCII-TS-MTC-
91, ( 15.40±0.15mm ), SPECIFICATION
89. ( 11.00±0.15mm ). Assembly
End User
No Effect
PAGE NO- 7 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

Nos once periodic inspection & 100% process
No Effect 2). Tool built up edge 2). Alarm & lock in machine for tool life excess inspection with Bore Dial Gauge (or) Air Plug
3). Key lock for un authorised access & Program Gauge & 4 Nos per Shift Xbar R Chart Inspected
Subsequent Operation 3). Wrong Tool selection with Air Plug Gauge.
Part get rejected at final inspection 4). Tool worn out
DIAMETER OVER ( ISCII-TS-MTC-PMP/C-R04 ) Preventive maintainance Record (ISCII-TS-MTC-
8 2 5 80
part
End User
HOLE DIAMETER No Effect
178
( Ø11.00(+0.001 to +0.011)mm )
No Effect 2). Tool wear out 2). Alarm & lock in machine for tool life excess Nos once periodic inspection & 100% process
3). Key lock for un authorised access & Program inspection with Bore Dial Gauge (or) Air Plug
Subsequent Operation 3). Wrong Tool selection Gauge & 4 Nos per Shift Xbar R Chart Inspected
with Air Plug Gauge.
DIAMETER Part get rejected at final inspection
8 3 4 96
UNDER SIZE Assembly
End User
No Effect
Subsequent Operation 3). Wrong Tool selection Nos once periodic inspection with Digital vernier
caliper
DEPTH OVER control for parameter
6 3 4 72
No Effect
End User
100.(04) No Effect
HOLE DEPTH ON Ø11.00
Ø11.00MM REAMER - ---
( 35.00±0.20mm )
1 PLACE Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
( DATUM "E"
OPPOSITE SIDE ) No Effect 2). Tool wear out 2). Alarm & lock in machine for tool life excess
caliper
7 3 4 84
End User
No Effect
1). Key lock for un authorised access & Program Master program verification at Job set up
control for parameter inspection & Shift once periodic inspection with
2). Key lock for un authorised access & Program CMM & 4 Nos per day Cpu Chart inspect with
control for parameter CMM
CIRCULARITY ON Ø11.00 Part get rejected at final inspection
OUT OF
183 B 8 2 6 96
SPECIFICATION
( e | 0.007 ) Assembly
End User
No Effect
Next Operation 1). Tool wear out (Life excess) 1). Alarm & lock in machine for tool life excess
Master program verification at Job set up
2). Key lock for un authorised access & Program inspection & Shift once periodic inspection with
No Effect 2). Wrong Tool selection
control for parameter Surface Roughness tester & 4 Nos per day Cpu
3). Key lock for un authorised access & Program Chart inspect with Surface Roughness tester
SURFACE FINISH ON Ø11.00 Subsequent Operation 3). Wrong offset
OUT OF 4). Preventive maintainance Plan
183 C Part get rejected at final inspection 8 4). Machine axis variation (machine wear) 2 4 64
( Ra 3.20
Rz 25 ) Assembly
Customer dissatisfaction at assembly
End User
Performance Low
PAGE NO- 8 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

POSITION ON Ø11.00 Part get rejected at final inspection
OUT OF
184 7 2 6 84
SPECIFICATION
( j | Ø0.30 | E | F-G | G ) Assembly
100.(04) End User

Ø11.00MM REAMER -
1 PLACE No Effect
( DATUM "E" 1). Key lock for un authorised access & Program
OPPOSITE SIDE ) Next Operation 1). Program change
CENTER DISTANCE ON Ø11.00 ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
OUT OF Part get rejected at final inspection
7 2 6 84
89. ( 11.00±0.15mm ). Assembly
End User
No Effect
No Effect 2). Tool built up edge 2). Alarm & lock in machine for tool life excess Nos once periodic inspection with Digital vernier
3). Key lock for un authorised access & Program caliper (or) Plug Gauge
6 3 5 90
part
End User
SPOT FACE DIAMETER
183 J No Effect
( Ø16.50±0.20mm )
3). Key lock for un authorised access & Program Nos once periodic inspection with Digital vernier
Subsequent Operation 3). Wrong Tool selection caliper (or) Plug Gauge
7 3 4 84
UNDER SIZE
Assembly
End User
No Effect
100. (05)
ES. 1352 (G 1/4)
PORT FORM TOOL
Ø16.50 & 11.80 - 1 No Effect 2). Tool built up edge 2). Alarm & lock in machine for tool life excess
PLACE Master program verification at Job set up and 5
( DATUM "E" Subsequent Operation 3). Wrong Tool selection Nos once periodic inspection with Digital Vernier
OPPOSITE SIDE ) Caliper
6 3 4 72
End User
No Effect
SPOT FACE DEPTH ON Ø16.50
183 S
( 4.90±0.10mm ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
Subsequent Operation 3). Wrong Tool selection Nos once periodic inspection with Digital Vernier
Caliper
DEPTH UNDER
7 5). Key lock for un authorised access & Program 3 4 84
SIZE Assembly 5). Wrong work offset
End User
No Effect
PAGE NO- 9 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

3). Key lock for un authorised access & Program inspection & Periodic inspection with CMM (or) 2D
Height Gauge
DISTANCE UNDER control for parameter
8 3 4 96
End User
SPOT FACE DEPTH DISTANCE ON No Effect

289 Ø16.50
Subsequent Operation 3). Wrong Tool selection inspection & Periodic inspection with CMM (or) 2D
Height Gauge
DISTANCE OVER control for parameter
End User
No Effect
control for parameter inspection with Surface Roughness tester
SURFACE FINISH ON Ø16.50 Subsequent Operation 3). Wrong offset
183 F Part get rejected at final inspection 6 4). Machine axis variation (machine wear) 2 4 48
( Ra 3.20
Rz 25 ) Assembly
100. (05) Customer dissatisfaction at assembly

ES. 1352 (G 1/4)
End User
PORT FORM TOOL
Ø16.50 & 11.80 - 1 Performance Low
PLACE
control for parameter Master program verification at Job set up & Day
OPPOSITE SIDE )
2). Key lock for un authorised access & Program once periodic inspection with CMM
CONCENTRICITY ON Ø16.50
183 N 7 2 6 84
SPECIFICATION
( r | Ø0.40 | D ) Assembly
End User
No Effect
control for parameter Master program verification at Job set up & Day
PERPENDICULARITY ON Ø16.50 ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
FACE OUT OF Part get rejected at final inspection
183 T 7 2 6 84
SPECIFICATION
( b | 0.10 | D ) Assembly
End User
No Effect
No Effect 2). Wrong Tool selection inspection with CMM (or) Profile Projector with
moulded paste
Subsequent Operation 3). Wrong offset
PORT 'C' BORE DIAMETER OUT OF Part get rejected at final inspection
132 K 6 2 4 48
(Ø15.10±0.10mm ) SPECIFICATION
Assembly
End User
No Effect
PAGE NO- 10 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

moulded paste
PORT 'C' BORE DIAMETER PORT 'C' BORE
132 K Part get rejected at final inspection 6 2 5 60
(Ø15.10±0.10mm ) MISSING
Assembly
End User
No Effect
PORT 'C' BORE RUNOUT ON ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
Ø15.10 OUT OF Part get rejected at final inspection
183 H 7 2 6 84
SPECIFICATION
( h | 0.10 | D ) Assembly
End User
No Effect
PORT 'C' BORE SURFACE FINISH Subsequent Operation 3). Wrong offset
ON Ø15.10
OUT OF Part get rejected at final inspection 4). Machine axis variation (machine wear)
132 G 6 ( ISCII-TS-MTC-PMP/C-R04 ) 2 4 48
SPECIFICATION
( Ra 3.20 Assembly
Rz 16 )
End User
100. (05)
ES. 1352 (G 1/4) Performance Low
PORT FORM TOOL
Ø16.50 & 11.80 - 1 Next Operation 1). Tool wear out (Life excess) 1). Alarm & lock in machine for tool life excess
PLACE Master program verification at Job set up
OPPOSITE SIDE ) control for parameter
moulded paste
Part get rejected at final inspection

PORT 'C' BORE ANGLE ON Ø15.10 OUT OF
183 I 6 2 4 48
( 15°±1° ) SPECIFICATION
Assembly
End User
No Effect
No Effect 2). Wrong Tool selection inspection with Profile Projector with moulded
paste
OUT OF Part get rejected at final inspection 6 2 4 48
SPECIFICATION
Assembly
End User
PORT 'C' BORE DEPTH ON Ø15.10 No Effect

183 O
( 2.30±0.20mm )
paste
DEPTH MISSING Part get rejected at final inspection 6 2 5 60
Assembly
End User
No Effect
PAGE NO- 11 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

paste

OUT OF
6 2 4 48
SPECIFICATION
Assembly
End User
PORT 'C' BORE OUTER NOSE
183 P RADIUS ON Ø15.10 No Effect
( R0.20±0.10mm X 45° )
paste
RADIUS MISSING Part get rejected at final inspection 6 2 5 60

Assembly
End User
No Effect
No Effect 2). Tool built up edge 2). Alarm & lock in machine for tool life excess Nos once periodic inspection with CMM (or)
3). Key lock for un authorised access & Program Digital vernier caliper
6 3 5 90
100. (05) part
ES. 1352 (G 1/4) End User
PORT FORM TOOL HOLE DIAMETER ON G 1/4
Ø16.50 & 11.80 - 1 --- No Effect
( Ø11.80±0.10mm )
PLACE Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
( DATUM "E"
OPPOSITE SIDE ) Possibility for tap broken 2). Tool wear out 2). Alarm & lock in machine for tool life excess Master program verification at Job set up and 5
3). Key lock for un authorised access & Program Nos once periodic inspection with CMM (or)
Subsequent Operation 3). Wrong Tool selection Digital vernier caliper
7 3 4 84
UNDER SIZE Assembly
End User
No Effect
POSITION ON G 1/4 PORT Part get rejected at final inspection
OUT OF
184 7 2 6 84
SPECIFICATION
( j | Ø0.30 | E | F-G | G ) Assembly
End User
No Effect
CENTER DISTANCE ON G 1/4 PORT Part get rejected at final inspection
91, OUT OF
7 2 6 84
89. ( 15.40±0.15mm ), SPECIFICATION Assembly
( 11.00±0.15mm ).
End User
No Effect
PAGE NO- 12 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

No Effect 2). Tool built up edge 2). Alarm & lock in machine for tool life excess Nos once periodic inspection with Groove vernier
3). Key lock for un authorised access & Program caliper (or) CMM
6 3 5 90
part
End User
GROOVE DIAMETER No Effect
183 Q
( Ø12.20±0.20mm )
3). Key lock for un authorised access & Program Nos once periodic inspection with Groove vernier
Subsequent Operation 3). Wrong Tool selection caliper (or) CMM
7 3 4 84
UNDER SIZE Assembly
End User
No Effect
Gauge
WIDTH OVER control for parameter
8 3 4 96
End User
100. (06)
Ø10.00MM No Effect
GROOVE WIDTH ON Ø12.20
GROOVING TOOL 183 V
( 4.50±0.20mm )
FOR 4.20 GROOVE
FINISHING - 1
PLACE
( DATUM "E" No Effect 2). Tool wear out 2). Alarm & lock in machine for tool life excess
Gauge
WIDTH UNDER Part get rejected at final inspection 4). Wrong Tool offset
SIZE
End User
No Effect
Gauge
DEPTH OVER Part get rejected at final inspection 4). Wrong Tool offset
SIZE
End User
GROOVE DEPTH ON Ø12.20 No Effect

183 U
( 42.15±0.20mm )
Gauge
DEPTH UNDER Part get rejected at final inspection 4). Wrong Tool offset
SIZE
End User
No Effect
PAGE NO- 13 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

POSITION ON Ø12.20 GROOVE Part get rejected at final inspection
OUT OF
184 7 2 6 84
SPECIFICATION
( j | Ø0.30 | E | F | G ) Assembly

100. (06)
Ø10.00MM End User
GROOVING TOOL
No Effect
FOR 4.20 GROOVE
FINISHING - 1 1). Key lock for un authorised access & Program
PLACE control for parameter Master program verification at Job set up
( DATUM "E" 2). Key lock for un authorised access & Program inspection with CMM
GROOVE Part get rejected at final inspection
91, OUT OF
7 2 6 84
89. SPECIFICATION
( 15.40±0.50mm ), Assembly
( 11.00±0.50mm ).
End User
No Effect
No Effect 2). Tap built up edge 2). Alarm & lock in machine for tool life excess Nos once periodic inspection & 100% Process
3). Key lock for un authorised access & Program Inspection with Thread Plug Gauge
Part get rejected at final inspection 4). Tap worn out
THREAD OVER ( ISCII-TS-MTC-PMP/C-R04 ) Preventive maintainance Record (ISCII-TS-MTC-
6 2 6 72
part
End User
THREAD No Effect
183 L
( G 1/4 )
No Effect 2). Tap wear out 2). Alarm & lock in machine for tool life excess Master program verification at Job set up and 5
3). Key lock for un authorised access & Program Nos once periodic inspection & 100% Process
Subsequent Operation 3). Wrong Tool selection Inspection with Thread Plug Gauge
THREAD UNDER Part get rejected at final inspection
7 2 6 84
SIZE Assembly
End User
No Effect
100.(07)
G 1/4 TAPPING - 1 Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
PLACE
( DATUM "E" No Effect 2). Tap built up edge 2). Alarm & lock in machine for tool life excess
Subsequent Operation 3). Wrong Tool selection Nos once periodic inspection for Digital vernier
caliper with Thread Plug Gauge
6 3 4 72
No Effect
End User
THREAD DEPTH ON G 1/4 No Effect

183 E
( x 9.50mm MIN )
No Effect 2). Tap wear out 2). Alarm & lock in machine for tool life excess
DEPTH UNDER Part get reworked at final inspection 4). Wrong Tool offset
SIZE
End User
No Effect
PAGE NO- 14 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

POSITION ON G1/4
184 7 2 6 84
SPECIFICATION
( j | Ø0.30 | E | F-G | G ) Assembly
End User
No Effect
100.(07) ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
G 1/4 TAPPING - 1 RUNOUT ON G 1/4
PLACE 184 M 7 2 6 84
SPECIFICATION
( DATUM "E" ( h | 0.10 | D ) Assembly
OPPOSITE SIDE )
End User
No Effect
CENTER DISTANCE ON G1/4
91, OUT OF Part get rejected at final inspection
7 2 6 84
89. ( 15.40±0.15mm ), SPECIFICATION
( 11.00±0.15mm ). Assembly
End User
No Effect
3). Key lock for un authorised access & Program caliper
6 3 5 90
part
End User
HOLE DIAMETER ON M10 X 1.50 -
--- 6H No Effect
( Ø8.50±0.10mm )
Possibility for tap broken 2). Tool wear out 2). Alarm & lock in machine for tool life excess Master program verification at Job set up and 5
Subsequent Operation 3). Wrong Tool selection caliper
100. (08) 7 3 4 84
UNDER SIZE Assembly
Ø8.50MM DRILLING -
3 PLACES
( DATUM "E" Tight Fitment problem not mating with mating part
OPPOSITE SIDE )
End User
No Effect
Caliper
HOLE DEPTH DISTANCE ON Ø8.50 Part get rejected at final inspection 4). Wrong Tool offset
179 OVER SIZE 6 control for parameter 3 4 72
( 49.00mm MIN )
End User
No Effect
PAGE NO- 15 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

Caliper
HOLE DEPTH DISTANCE ON Ø8.50 control for parameter
179 UNDER SIZE 7 3 4 84
( 49.00mm MIN ) 5). Key lock for un authorised access & Program
End User
No Effect
paste
DIAMETER OUT Part get rejected at final inspection

OF 6 2 4 48
SPECIFICATION Assembly
End User
CHAMFER DIAMETER ON Ø8.50
186
( Ø10.50mm MAX ) No Effect
paste
CHAMFER
MISSING
Assembly
Ø8.50MM DRILLING -
3 PLACES End User
( DATUM "E" No Effect
OPPOSITE SIDE )
paste
CHAMFER ANGLE ON Ø8.50 OUT OF Part get rejected at final inspection
187 6 2 4 48
( 45°±0°30' ) SPECIFICATION
Assembly
End User
No Effect
POSITION ON Ø8.50
188 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G )
Assembly
End User
No Effect
---, ( 0.00±0.30mm ), SPECIFICATION
90. ( 1.70±0.30mm ). Assembly
End User
No Effect
PAGE NO- 16 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

THREAD OVER Part get rejected at final inspection 4). Tap worn out
part
End User
THREAD
185 No Effect
( M10 X 1.50 - 6H )
7 2 6 84
SIZE Assembly
End User
No Effect
No Effect 2). Tap built up edge 2). Alarm & lock in machine for tool life excess
6 3 4 72
No Effect
End User
100. (09) THREAD DEPTH DISTANCE ON No Effect

M10 X 1.50 - 6H 180 M10 X 1.50 - 6H
TAPPING - 1 PLACE ( 53.50mm MAX ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
( DATUM "E"
OPPOSITE SIDE ) No Effect 2). Tap wear out 2). Alarm & lock in machine for tool life excess
Part get reworked at final inspection 4). Wrong Tool offset
7 3 4 84
End User
No Effect
POSITION ON M10 X 1.50 -6H
188 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G )
Assembly
End User
No Effect
CENTER DISTANCE ON M10 X 1.50 - ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
6H Part get rejected at final inspection
OUT OF
7 2 6 84
SPECIFICATION
---, ( 0.00±0.30mm ), Assembly
90. ( 1.70±0.30mm ).
End User
No Effect
PAGE NO- 17 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

No Effect 2). Tool built up edge 2). Alarm & lock in machine for tool life excess Nos once periodic inspection with CMM (or) Plug
3). Key lock for un authorised access & Program Gauge
6 3 5 90
part
End User
193
( Ø8.00±0.50mm )
3). Key lock for un authorised access & Program Nos once periodic inspection with CMM (or) Plug
Subsequent Operation 3). Wrong Tool selection Gauge
7 3 4 84
UNDER SIZE Assembly
End User
No Effect
Caliper (or) Depth Gauge
6 3 4 72
End User
100.(10) HOLE DEPTH ON Ø8.00 No Effect

Ø8.00MM DRILLING - 194
( x 50.00±0.50mm )
( DATUM "E"
OPPOSITE SIDE ) No Effect 2). Tool wear out 2). Alarm & lock in machine for tool life excess
7 3 4 84
End User
No Effect
control for parameter Master program verification at Job set up & Shift
POSITION ON Ø8.00
196 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F | G )
Assembly
End User
No Effect
CENTER DISTANCE ON Ø8.00
OUT OF
7 2 6 84
Assembly
98. ( 21.00±0.40mm ).
End User
No Effect
PAGE NO- 18 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

6 3 5 90
part
End User
SPOT FACE DIAMETER
195 L No Effect
( Ø25.00(-0.00 to +0.40)mm )
7 3 4 84
UNDER SIZE
Assembly
End User
No Effect
Caliper
6 3 4 72
End User
100. (11)
502B0059 5.1 (6S No Effect
SAE) PORT FORM SPOT FACE DEPTH ON Ø25.00
TOOL 195 F
( 1.00mm MAX ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
( Ø10.00 & Ø9.60 ) - 1
PLACE
( DATUM "E"
Caliper
DEPTH UNDER
End User
No Effect
3). Key lock for un authorised access & Program Master program verification at Job set up and Day
Subsequent Operation 3). Wrong Tool selection once periodic inspection with CMM (or) 2D Height
Gauge
DISTANCE UNDER 4). Key lock for un authorised access & Program
End User
SPOT FACE DISTANCE ON Ø25.00 No Effect
102 FACE
( 66.00±0.50mm )
Gauge
DISTANCE OVER 4). Key lock for un authorised access & Program
End User
No Effect
PAGE NO- 19 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

SURFACE FINISH ON Ø25.00 FACE 4). Preventive maintainance Plan
195 B 6 ( ISCII-TS-MTC-PMP/C-R04 ) 2 4 48
SPECIFICATION
( 3.20 Rz 25 ) Assembly
End User
Performance Low
PERPENDICULARITY ON Ø25.00
FACE Part get rejected at final inspection
OUT OF
195 R 7 2 6 84
SPECIFICATION
Assembly
( b | 0.10 | A )
End User
No Effect
PORT 'C' BORE RUNOUT ON
Ø15.60 Part get rejected at final inspection
OUT OF
195 M 7 2 6 84
SPECIFICATION
Assembly
( h | 0.10 | A )
100. (11)
502B0059 5.1 (6S End User
SAE) PORT FORM
TOOL No Effect
( Ø10.00 & Ø9.60 ) - 1
PLACE Next Operation 1). Tool wear out (Life excess) 1). Alarm & lock in machine for tool life excess
( DATUM "E" 2). Key lock for un authorised access & Program Master program verification at Job set up
OPPOSITE SIDE ) No Effect 2). Wrong Tool selection
PORT 'C' BORE SURFACE FINISH control for parameter
ON Ø15.60 4). Preventive maintainance Plan
195 N 6 ( ISCII-TS-MTC-PMP/C-R04 ) 2 4 48
SPECIFICATION
Assembly
( 1.60 Rz 16 )
End User
Performance Low
paste
6 2 4 48
SPECIFICATION
Assembly
End User
CHAMFER HEIGHT ON Ø15.60
No Effect
195 A
( -0.10
-0.30 )
paste
CHAMFER Part get rejected at final inspection 6 2 5 60
MISSING
Assembly
End User
No Effect
PAGE NO- 20 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

Caliper
SIZE
End User

195 C
( 17.00(-0.00 to +1.00)mm )
3). Key lock for un authorised access & Program Master program verification at Job set up and 5
4). Key lock for un authorised access & Program Caliper
7 3 4 84
End User
No Effect
paste
6 2 4 48
SPECIFICATION
Assembly

100. (11)
502B0059 5.1 (6S End User
SAE) PORT FORM
TOOL PORT 'C' BORE DEPTH ON Ø15.60 No Effect
( Ø10.00 & Ø9.60 ) - 1 195 E
( 2.50(-0.00 to +0.40)mm )
PLACE Next Operation 1). Tool wear out (Life excess) 1). Alarm & lock in machine for tool life excess
( DATUM "E" Master program verification at Job set up
OPPOSITE SIDE ) No Effect 2). Wrong Tool selection inspection with Profile Projector with moulded
paste
RADIUS MISSING 6 2 5 60
Assembly
End User
No Effect
paste
6 2 4 48
SPECIFICATION
Assembly
End User
NOSE RADIUS ON Ø15.60 No Effect

195 I
( R0.20±0.10mm )
paste
Assembly
End User
No Effect
PAGE NO- 21 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

moulded paste
6 2 4 48
SPECIFICATION
Assembly
End User
PORT 'C' BORE DIAMETER No Effect
195 K
( Ø15.60(-0.00 to +0.13)mm )
moulded paste
PORT 'C' BORE
MISSING
Assembly
End User
No Effect
paste
TIP ANGLE ON Ø12.80 OUT OF Part get rejected at final inspection
195 G 6 2 4 48
( 118° MIN ) SPECIFICATION
Assembly
End User
100. (11)
502B0059 5.1 (6S No Effect
SAE) PORT FORM
TOOL Next Operation 1). Tool wear out (Life excess) 1). Alarm & lock in machine for tool life excess
( Ø10.00 & Ø9.60 ) - 1 Master program verification at Job set up
PLACE 2). Key lock for un authorised access & Program
( DATUM "E" control for parameter
paste
OPPOSITE SIDE ) 3). Key lock for un authorised access & Program

195 O 6 2 4 48
Assembly
End User
No Effect
DIAMETER OVER Part get rejected at final inspection 4). Tool worn out
part
End User
No Effect
HOLE DIAMETER ON 9/16 - 18 UNF
195 J ( Ø14.30mm Approx ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
( Ø12.80±0.10mm ). No Effect 2). Tool wear out 2). Alarm & lock in machine for tool life excess
control for parameter Digital vernier caliper

DIAMETER
Assembly 7 3 4 84
UNDER SIZE
End User
No Effect
PAGE NO- 22 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

PORT 'C' BORE CONCENTRICITY
ON Ø15.60 Part get rejected at final inspection
OUT OF
195 P 7 2 6 84
SPECIFICATION
Assembly
( r | Ø0.30 | A )
End User
No Effect
paste

ANGLE ON Ø15.60 BOTTOM AREA OUT OF
195 Q 6 2 4 48
Assembly

502B0059 5.1 (6S
SAE) PORT FORM
End User
TOOL
( Ø10.00 & Ø9.60 ) - 1
PLACE No Effect
( DATUM "E"
OPPOSITE SIDE ) Next Operation 1). Program change
POSITION ON 6 SAE, 9/16-18 UN
PORT Part get rejected at final inspection
OUT OF
196 7 2 6 84
SPECIFICATION
Assembly
( j | Ø0.80 | E | F-G | G )
End User
No Effect
CENTER DISTANCE ON 6 SAE, 9/16- 3). Preventive maintainance Plan Preventive maintainance Record (ISCII-TS-MTC-
18 UN PORT ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
SPECIFICATION
95, ( 129.00±0.40mm ),
Assembly
98. ( 21.00±0.40mm ).
End User
No Effect
6 2 6 72
part
100.(12) End User
9/16 - 18 UNF
THREAD No Effect
TAPPING - 1 PLACE 195 J
( 9/16 - 18 UNF )
( DATUM "E"
OPPOSITE SIDE )
7 2 6 84
SIZE Assembly
End User
No Effect
PAGE NO- 23 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

6 3 4 72
No Effect
End User
THREAD DEPTH ON 9/16 - 18 UNF No Effect

195 D
( x 12.70mm MIN )
SIZE
100.(12)
9/16 - 18 UNF End User
TAPPING - 1 PLACE
OPPOSITE SIDE )
POSITION ON 9/16-18 UN
196 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F | G )
Assembly
End User
No Effect
CENTER DISTANCE ON 9/16-18 UN ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
98. ( 21.00±0.40mm ). Assembly
End User
No Effect
No Effect 2). Tool built up edge 2). Alarm & lock in machine for tool life excess Nos once periodic inspection with Digital Vernier
3). Key lock for un authorised access & Program Caliper (or) Plug Gauge
6 3 5 90
part
End User
100. (13)
Ø5.00MM DRILLING - No Effect
HOLE DIAMETER 8
1 PLACE 198 B
( Ø5.00(-0.00 to +0.10)mm ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
( DATUM "E"
OPPOSITE SIDE ) No Effect 2). Tool wear out 2). Alarm & lock in machine for tool life excess Master program verification at Job set up and 5
3). Key lock for un authorised access & Program Nos once periodic inspection with Digital Vernier
Subsequent Operation 3). Wrong Tool selection Caliper (or) Plug Gauge
DIAMETER
Assembly 7 3 4 84
UNDER SIZE
End User
No Effect
PAGE NO- 24 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

control for parameter Master program verification at Job set up and Day
CIRCULARITY ON Ø5.00
OUT OF
198 C. 7 2 6 84
SPECIFICATION
Assembly
( e | 0.05 )
End User
No Effect
control for parameter Nos once periodic inspection with Digital Vernier
4). Key lock for un authorised access & Program Caliper (or) Depth Gauge
DISTANCE UNDER
6 3 4 72
End User
198 E.
( x7.00±0.50mm ) No Effect
DISTANCE OVER Part get rejected at final inspection 4). Wrong Tool offset
SIZE
100. (13) 5). Key lock for un authorised access & Program
Ø5.00MM DRILLING - control for parameter
1 PLACE
( DATUM "E" Fitment problem not mating with mating part
OPPOSITE SIDE )
End User
No Effect
No Effect 2). Wrong Tool selection once periodic inspection with Surface Roughness
tester
SURFACE FINISH ON Ø5.00 control for parameter
198 D. Part get rejected at final inspection 6 4). Machine axis variation (machine wear) 2 5 60
(2 X Rz 7 to 30 ) Assembly
End User
Performance Low
6 3 5 90
part
HOLE DIAMETER End User
198 F.
( Ø5.00±0.10mm )
No Effect
DIAMETER
7 3 4 84
UNDER SIZE Part get rejected at final inspection
Assembly
End User
No Effect
PAGE NO- 25 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

Caliper
6 3 4 72
End User

199
( x60.00±0.50mm ).
Caliper
7 3 4 84

100. (13)
Ø5.00MM DRILLING - End User
1 PLACE
OPPOSITE SIDE )
POSITION ON Ø5.00
OUT OF
200 7 2 6 84
SPECIFICATION
Assembly
( j | Ø0.80 | E | F-G | G )
End User
No Effect
99. ( 46.00±0.40mm ). Assembly
End User
No Effect
6 3 PMP-R05) with CMK study 5 90
SIZE 5). Preventive maintainance Plan
part
100. (14) End User
Ø10.00MM END SPOT FACE DIAMETER
MILLING - 1 PLACE 197 No Effect
( vØ10.00±0.40mm )
( DATUM "E"
OPPOSITE SIDE ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
7 3 4 84
UNDER SIZE
Assembly
End User
No Effect
PAGE NO- 26 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

Subsequent Operation 3). Wrong Tool selection Nos once periodic inspection with CMM (or) 2D
Height Gauge
DEPTH DISTANCE control for parameter
6 3 4 72
UNDER SIZE 5). Key lock for un authorised access & Program
No Effect
End User

102 Ø10.00
Height Gauge
7 3 4 84
OVER SIZE 5). Key lock for un authorised access & Program
100. (14) control for parameter
Ø10.00MM END
MILLING - 1 PLACE
( DATUM "E"
End User
OPPOSITE SIDE )
No Effect
POSITION ON Ø10.00 3). Preventive maintainance Plan Preventive maintainance Record (ISCII-TS-MTC-
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
No Effect
99. ( 46.00±0.40mm ). Assembly
End User
No Effect
Caliper (or) Plug Gauge
6 3 5 90
part
End User
100. (15)
Ø30.00MM END
MILLING - 1 PLACE 189
( Ø30.00±0.40mm )
( DATUM "E"
Nos once periodic inspection with Digital Vernier

7 3 4 84
UNDER SIZE
Assembly
End User
No Effect
PAGE NO- 27 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

Can not achive the dimension 33.00±0.50mm in

2). Tool built up edge 2). Alarm & lock in machine for tool life excess
120th process and get rejected at 120th process
Caliper
6 3 4 72
End User

190
( x30.00±0.50mm ).
Load for the 120th process will be high and it may

Caliper
7 3 4 84

100. (15)
Ø30.00MM END End User
MILLING - 1 PLACE
OPPOSITE SIDE )
POSITION ON Ø30.00
OUT OF
192 7 2 6 84
SPECIFICATION
Assembly
( j | Ø0.80 | E | F-G | G )
End User
No Effect
SPECIFICATION
92, ( 62.90±0.40mm ), Assembly
97. ( 9.00±0.40mm ).
End User
No Effect
6 3 5 90
100. (16) part
502B0059 5.1 (16
End User
SAE) PORT FORM
SPOT FACE DIAMETER
TOOL ( Ø49.00 & 191 L No Effect
( Ø49.00(-0.00 to +0.40)mm )
Ø31.20 ) - 1 PLACE
( DATUM "E" Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
OPPOSITE SIDE ) No Effect 2). Tool wear out 2). Alarm & lock in machine for tool life excess Master program verification at Job set up and 5
7 3 4 84
UNDER SIZE
Assembly
End User
No Effect
PAGE NO- 28 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

Caliper
6 3 4 72
End User
SPOT FACE DEPTH ON Ø49.00 No Effect

191 F
( 2.00mm MAX )
Caliper
End User
No Effect
Master program verification at Job set up and Day
Gauge
DISTANCE UNDER Part get rejected at final inspection 4). Wrong Tool offset
SIZE
100. (16)
502B0059 5.1 (16 Fitment problem not mating with mating part
SAE) PORT FORM
TOOL ( Ø49.00 & End User
Ø31.20 ) - 1 PLACE SPOT FACE DISTANCE ON Ø49.00
No Effect
( DATUM "E" 102 FACE
OPPOSITE SIDE ) ( 66.00±0.50mm ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
Gauge
End User
No Effect
SURFACE FINISH ON Ø49.00 FACE control for parameter
191 B Part get rejected at final inspection 6 4). Machine axis variation (machine wear) 2 4 48

End User
Performance Low
PERPENDICULARITY ON Ø49.00 ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
FACE OUT OF Part get rejected at final inspection
191 R 7 2 6 84
SPECIFICATION
( b | 0.20 | A ) Assembly
End User
No Effect
PAGE NO- 29 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

OUT OF
191 M 7 2 6 84
SPECIFICATION
Assembly
( h | 0.10 | A )
End User
No Effect
SPECIFICATION
Assembly
( 1.60 Rz 16 )
End User
Performance Low
paste
6 2 4 48
SPECIFICATION
Assembly

100. (16)
502B0059 5.1 (16 End User
SAE) PORT FORM CHAMFER HEIGHT ON Ø35.50
TOOL ( Ø49.00 & No Effect
Ø31.20 ) - 1 PLACE 191 A
( DATUM "E" ( -0.10
OPPOSITE SIDE ) -0.30 )
paste
MISSING
Assembly
End User
No Effect
Caliper
End User
191 C
( 26.00(-0.00 to +1.00)mm )
control for parameter Caliper
End User
No Effect
PAGE NO- 30 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

paste

OUT OF
6 2 4 48
SPECIFICATION
Assembly
End User
PORT 'C' BORE DEPTH ON Ø35.50

191 E No Effect
( 3.30(-0.00 to +0.40)mm )
paste

Assembly
End User
No Effect
paste

OUT OF
6 2 4 48
SPECIFICATION
Assembly
100. (16)
502B0059 5.1 (16
SAE) PORT FORM
TOOL ( Ø49.00 & End User
Ø31.20 ) - 1 PLACE NOSE RADIUS ON Ø35.50
( DATUM "E" 191 I No Effect
( R0.20±0.10mm )
OPPOSITE SIDE )
paste

Assembly
End User
No Effect
paste
OUT OF
SPECIFICATION
Assembly

End User
191 K
( Ø35.50(-0.00 to +0.13)mm )
paste
PORT 'C' BORE
MISSING
Assembly
End User
No Effect
PAGE NO- 31 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

paste
191 G 6 2 4 48
Assembly
End User
No Effect
part
HOLE DIAMETER ON 1 5/16 - 12 UN End User
191 J ( Ø33.40mm Approx ) No Effect
191 H ( Ø31.20±0.10mm ).
7 3 4 84
UNDER SIZE Assembly
End User
No Effect
100. (16)
502B0059 5.1 (16
SAE) PORT FORM 2). Key lock for un authorised access & Program
TOOL ( Ø49.00 & control for parameter
paste
Ø31.20 ) - 1 PLACE 3). Key lock for un authorised access & Program
( DATUM "E" Subsequent Operation 3). Wrong offset
OPPOSITE SIDE )
191 O 6 2 4 48
Assembly
End User
No Effect

OUT OF
191 P 7 2 6 84
SPECIFICATION
Assembly
( r | Ø0.30 | A )
End User
No Effect
paste
191 Q Part get rejected at final inspection 6 2 4 48
Assembly
End User
No Effect
PAGE NO- 32 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

POSITION ON 16 SAE, 1 5/16-12 UN
OUT OF
192 7 2 6 84
SPECIFICATION
Assembly
( j | Ø0.80 | E | F-G | G )
100. (16) End User

502B0059 5.1 (16
SAE) PORT FORM No Effect
TOOL ( Ø49.00 &
Ø31.20 ) - 1 PLACE Next Operation 1). Program change
( DATUM "E"
OPPOSITE SIDE ) No Effect 2). Wrong work offset
CENTER DISTANCE ON 16 SAE, 1 ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
5/16-12 UN PORT Part get rejected at final inspection
OUT OF
7 2 6 84
SPECIFICATION
92, ( 62.90±0.40mm ), Assembly
97. ( 9.00±0.40mm ).
End User
No Effect
part
End User
THREAD
191 J No Effect
( 1 5/16 - 12 UN )
7 2 6 84
SIZE Assembly
End User
No Effect
100. (17) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
16 SAE, 1 5/16 - 12
UN TAPPING - 1
PLACE
6 3 4 72
No Effect
End User
THREAD DEPTH ON 1 5/16 - 12 UN No Effect

191 D
( x 19.00mm MIN )
7 3 4 84
End User
No Effect
PAGE NO- 33 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

POSITION ON 1 5/16 - 12 UN Part get rejected at final inspection
OUT OF
192 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
100. (17) End User

16 SAE, 1 5/16 - 12
No Effect
UN TAPPING - 1
PLACE 1). Key lock for un authorised access & Program
CENTER DISTANCE ON 1 5/16 - 12 ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
UN Part get rejected at final inspection
OUT OF
7 2 6 84
SPECIFICATION
92, ( 62.90±0.40mm ), Assembly
97. ( 9.00±0.40mm ).
End User
No Effect
6 3 5 90
part
End User
SPOT FACE DIAMETER
181 L No Effect
( Ø58.90(-0.00 to +0.40)mm )
7 3 4 84
UNDER SIZE
Assembly
End User
No Effect
100.(18)
502B0059 5.1 (20 Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
SAE) PORT FORM
TOOL - 1 PLACE No Effect 2). Tool built up edge 2). Alarm & lock in machine for tool life excess
( DATUM "E" Master program verification at Job set up and 5
Caliper
6 3 4 72
End User

181 F
( 2.00mm MAX )
Caliper
End User
No Effect
PAGE NO- 34 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

3). Key lock for un authorised access & Program once periodic inspection with CMM (or) 2D Height
Gauge
6 3 4 72
End User

102 FACE
Gauge
7 3 4 84
End User
No Effect
SPECIFICATION
100.(18) End User

502B0059 5.1 (20
SAE) PORT FORM Performance Low
TOOL - 1 PLACE
OPPOSITE SIDE )
OUT OF
181 R 7 2 6 84
SPECIFICATION
Assembly
( b | 0.20 | A )
End User
No Effect
paste
6 2 4 48
SPECIFICATION
Assembly
CHAMFER HEIGHT ON Ø43.50 End User
181 A No Effect
( -0.10
-0.30 ) Next Operation 1). Tool wear out (Life excess) 1). Alarm & lock in machine for tool life excess
paste
CHAMFER
MISSING
Assembly
End User
No Effect
PAGE NO- 35 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

Caliper
6 3 4 72
End User

181 C
( 26.00(-0.00 to +1.00)mm )
Caliper
SIZE
End User
No Effect
paste

OUT OF
6 2 4 48
SPECIFICATION
Assembly
100.(18) Customer dissatisfaction at assembly

502B0059 5.1 (20
SAE) PORT FORM End User
TOOL - 1 PLACE
( DATUM "E" PORT 'C' BORE DEPTH ON Ø43.50
181 E No Effect
OPPOSITE SIDE ) ( 3.30(-0.00 to +0.40)mm )
paste

Assembly
End User
No Effect
paste
OUT OF
SPECIFICATION
Assembly
End User
181 I
( R0.20±0.10mm )
paste
Assembly
End User
No Effect
PAGE NO- 36 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

part
End User
HOLE DIAMETER ON 1 5/8 - 12 UN
No Effect
181 J ( Ø41.30mm Approx )
181 H ( Ø39.10±0.10mm ). Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
DIAMETER Assembly 7 3 4 84
UNDER SIZE
End User
No Effect
paste
181 G 6 2 4 48
Assembly
End User
No Effect
100.(18)
502B0059 5.1 (20 Next Operation 1). Tool wear out (Life excess) 1). Alarm & lock in machine for tool life excess
SAE) PORT FORM Master program verification at Job set up
TOOL - 1 PLACE 2). Key lock for un authorised access & Program
paste
6 2 4 48
SPECIFICATION
Assembly
End User
No Effect
PORT 'C' BORE DIAMETER
181 K
( Ø43.50(-0.00 to +0.13)mm ) Next Operation 1). Tool wear out (Life excess) 1). Alarm & lock in machine for tool life excess
paste
PORT 'C' BORE Part get rejected at final inspection

6 2 5 60
MISSING
Assembly
End User
No Effect
Ø43.50 OUT OF
181 M 7 2 6 84
( h | 0.10 | A )
End User
No Effect
PAGE NO- 37 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN
OPERATION NO :- 10 RAW MATERIAL FROM FOUNDRY TO MACHINE

` SHOP 1). Tool wear out (Life excess) 1). Alarm & lock in machine for tool life excess
SPECIFICATION
Assembly
( 1.60 Rz 16 )
End User
Performance Low
paste

181 O 6 2 4 48
Assembly
End User
No Effect
PORT 'C' BORE CONCENTRICITY ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
ON Ø43.50 OUT OF Part get rejected at final inspection
181 P 7 2 6 84
SPECIFICATION
( r | Ø0.30 | A ) Assembly
100.(18) Fitment problem not mating with mating part

502B0059 5.1 (20
TOOL - 1 PLACE No Effect
( DATUM "E"
OPPOSITE SIDE ) Next Operation 1). Tool wear out (Life excess) 1). Alarm & lock in machine for tool life excess
paste
ANGLE ON Ø43.50 BOTTOM AREA OUT OF control for parameter
181 Q 6 2 4 48
( 45°±5° ) SPECIFICATION Part get rejected at final inspection
Assembly
End User
No Effect
POSITION ON 20 SAE, 1 5/8-12 UN
OUT OF
182 7 2 6 84
SPECIFICATION
Assembly
( j | Ø0.80 | E | F-G | G )
End User
No Effect
CENTER DISTANCE ON 20 SAE, 1 ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
5/8-12 UN PORT Part get rejected at final inspection
OUT OF
7 2 6 84
SPECIFICATION
93, ( 89.00±0.40mm ), Assembly
100. ( 94.00±0.40mm ).
End User
No Effect
PAGE NO- 38 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

RAW MATERIAL FROM FOUNDRY TO MACHINE SHOP 1). Improper M/C Setup 1). Proper checked JSIR
6 2 6 72
part
End User
THREAD No Effect
181 J
( 1 5/8 - 12 UN )
7 2 6 84
SIZE Assembly
End User
No Effect
6 3 4 72
No Effect
End User
THREAD DEPTH ON 1 5/8 - 12 UN No Effect

181 D
( x 19.00mm MIN )
20 SAE, 1 5/8 - 12 UN
TAPPING - 1 PLACE No Effect 2). Tap wear out 2). Alarm & lock in machine for tool life excess
( DATUM "E" Master program verification at Job set up and 5
7 3 4 84
End User
No Effect
POSITION ON 1 5/8 - 12 UN Part get rejected at final inspection
OUT OF
182 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
No Effect
CENTER DISTANCE ON 1 5/8 - 12
UN Part get rejected at final inspection
OUT OF
7 2 6 84
93, ( 89.00±0.40mm ),
100. ( 94.00±0.40mm ).
End User
No Effect
PAGE NO- 39 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

caliper
6 3 5 90
part
End User
SPOT FACE DIAMETER FOR "P" & No Effect

--- "T" PUNCH PURPOSE
( 2 X Ø10.00±0.25mm ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
Nos once periodic inspection with Digital vernier

DIAMETER
7 3 4 84
UNDER SIZE
Assembly
End User
No Effect
100.(20) Subsequent Operation 3). Wrong Tool selection Nos once periodic inspection with Digital Vernier
Ø10.00MM END Caliper
MILLING - 2 PLACES Part get rejected at final inspection 4). Wrong Tool offset
( FOR "P" & "T" 6 3 4 72
PUNCH PURPOSE ) Assembly 5). Wrong work offset
End User

--- Ø10.00 FOR "P" & "T" PUNCH
( 2 X 66.00±0.20mm ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
Caliper
7 3 4 84
End User
No Effect

CENTER DISTANCE ONØ10.00 ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study

( 115.00±0.25mm ), OUT OF
---- 7 2 6 84
( 100.00±0.25mm ), Assembly
( 130.00±0.25mm ).
End User
No Effect
PAGE NO- 40 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN
OPERATION
FIXTURE NO 90°
INDEX :- 10 RAW MATERIAL FROM FOUNDRY TO MACHINE SHOP
6 3 5 90
part
End User
228, 177
( Ø7.00±0.50mm )
7 3 4 84
UNDER SIZE Assembly
End User
No Effect
3). Key lock for un authorised access & Program Master program verification at Job set up and
control for parameter Shift once periodic inspection with CMM
SIZE
End User
100. (21) 229
Ø7.00MM DRILLING - ( x 157.00±0.50mm )
( A1 -SIDE )
3). Key lock for un authorised access & Program Master program verification at Job set up and
control for parameter Shift once periodic inspection with CMM
End User
No Effect
OUT OF
231 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
No Effect
7 2 6 84
107. ( 13.50±0.50mm ). Assembly
End User
No Effect
PAGE NO- 41 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

6 3 5 90
part
End User
SPOT FACE DIAMETER
230 B No Effect
( Ø15.80(-0.05 to +0.10)mm )
7 3 4 84
UNDER SIZE
Assembly
End User
No Effect
Caliper (or) Profile Projector with moulded paste
6 3 4 72
End User
100. (22)
No Effect
OSV PER 155M5833 SPOT FACE DEPTH ON Ø15.80
230 G
PORT FORM TOOL ( 11.70mm MIN )
( Ø15.80, Ø14.60, Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
13.00 & 10.60 ) - 1
PLACE No Effect 2). Tool wear out 2). Alarm & lock in machine for tool life excess
( A1 -SIDE ) Master program verification at Job set up and 5
7 3 4 84
End User
No Effect
CONCENTRICITY ON Ø15.80 Part get rejected at final inspection
OUT OF
230 A 7 2 6 84
SPECIFICATION
( r | 0.05 | A ) Assembly
End User
No Effect
paste
CHAMFER ANGLE ON Ø15H8 OUT OF Part get rejected at final inspection
230 U 6 2 4 48
Assembly
End User
No Effect
PAGE NO- 42 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

paste
CHAMFER ANGLE ON M14 X 1.00 -
230 S 6H 6 2 4 48
SPECIFICATION
( 90°±5° )
Assembly
End User
No Effect
Subsequent Operation 3). Wrong Tool selection inspection with Profile Projector with moulded
paste
6 3 4 72
End User
No Effect
HOLE DEPTH ON M14 X 1.00 - 6H
230 J
paste
DEPTH UNDER
100. (22)
OSV PER 155M5833 Fitment problem not mating with mating part
PORT FORM TOOL (
Ø15.80, Ø14.60, End User
13.00 & 10.60 ) - 1
PLACE
( A1 -SIDE ) No Effect
paste
ANGLE ON Ø11H8 START AREA OUT OF Part get rejected at final inspection
230 R 6 2 4 48
Assembly
End User
No Effect
No Effect 2). Tool built up edge 2). Alarm & lock in machine for tool life excess Master program verification at Job set up
inspection with CMM
6 3 5 90
part
End User
TIP DIAMETER
230 M No Effect
( Ø7.00mm MAX )
7 3 4 84
UNDER SIZE
Assembly
End User
No Effect
PAGE NO- 43 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

No Effect 2). Tool built up edge 2). Alarm & lock in machine for tool life excess Master program verification at Job set up
inspection with CMM (or) Inside Vernier
6 3 5 90
part
End User
HOLE DIAMETER
230 N No Effect
( Ø10.50mm MIN )
3). Key lock for un authorised access & Program inspection with CMM (or) Inside Vernier
7 3 4 84
UNDER SIZE
Assembly
End User
No Effect
paste (or) Digital Vernier Caliper
6 3 4 72
End User
100. (22) No Effect

OSV PER 155M5833 HOLE DEPTH ON M14 X 1.00 - 6H
PORT FORM TOOL ( 230 K
( 38.55(-0.00 to +0.20)mm ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
Ø15.80, Ø14.60,
13.00 & 10.60 ) - 1
PLACE
( A1 -SIDE ) Master program verification at Job set up
DEPTH UNDER
End User
No Effect
4). Key lock for un authorised access & Program paste (or) 2D Height Master
6 3 4 72
End User
TANK HOLE POSITION DISTANCE No Effect

230 P
( 22.00±0.50mm )
4). Key lock for un authorised access & Program paste (or) 2D Height Master
End User
No Effect
PAGE NO- 44 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

OUT OF
231 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
100. (22) End User

OSV PER 155M5833
PORT FORM TOOL ( No Effect
Ø15.80, Ø14.60, 1). Key lock for un authorised access & Program
13.00 & 10.60 ) - 1 Next Operation 1). Program change
PLACE 2). Key lock for un authorised access & Program inspection with CMM
( A1 -SIDE ) No Effect 2). Wrong work offset
CENTER DISTANCE ON Ø15.80 Part get rejected at final inspection
OUT OF
7 2 6 84
113, ( 102.00±0.40mm ), SPECIFICATION Assembly
107. ( 13.50±0.40mm ).
End User
No Effect
Nos once periodic & 100% process inspection with
No Effect 2). Tool built up edge 2). Alarm & lock in machine for tool life excess Air Plug Gauge (or) Plug Gauge
3). Key lock for un authorised access & Program & 4 Nos per Shift Xbar R chart inspected with Air
Subsequent Operation 3). Wrong Tool selection Plug Gauge
8 2 5 80
part
End User
HOLE DIAMETER
230 C No Effect
( Ø15H8(-0.000 to +0.027)mm )
No Effect 2). Tool wear out 2). Alarm & lock in machine for tool life excess Nos once periodic & 100% process inspection with
3). Key lock for un authorised access & Program Air Plug Gauge (or) Plug Gauge
Subsequent Operation 3). Wrong Tool selection & 4 Nos per Shift Xbar R chart inspected with Air
Plug Gauge
8 3 4 96
UNDER SIZE
Assembly
End User
No Effect
100. (23)
Ø15H8 & Ø11H8
COMBINATION
REAMER - 1 PLACE No Effect 2). Tool built up edge 2). Alarm & lock in machine for tool life excess
paste
SIZE
End User
No Effect
HOLE DEPTH ON Ø15H8
230 H
( 3.50±0.20mm )
paste
7 3 4 84
End User
No Effect
PAGE NO- 45 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

SURFACE FINISH ON Ø15H8 4). Preventive maintainance Plan
230 E 6 ( ISCII-TS-MTC-PMP/C-R04 ) 2 4 48
SPECIFICATION
End User
Performance Low
Nos once periodic & 100% process inspection with
No Effect 2). Tool built up edge 2). Alarm & lock in machine for tool life excess Air Plug Gauge (or) Plug Gauge
3). Key lock for un authorised access & Program & 4 Nos per Shift Xbar R chart inspected with Air
Subsequent Operation 3). Wrong Tool selection Plug Gauge
8 2 5 80
part
End User
HOLE DIAMETER
230 F No Effect
( Ø11H8(-0.000 to +0.027)mm )
No Effect 2). Tool wear out 2). Alarm & lock in machine for tool life excess Nos once periodic & 100% process inspection with
3). Key lock for un authorised access & Program Air Plug Gauge (or) Plug Gauge
Subsequent Operation 3). Wrong Tool selection & 4 Nos per Shift Xbar R chart inspected with Air
Plug Gauge
8 3 4 96
UNDER SIZE
Assembly
End User
No Effect
Ø15H8 & Ø11H8
COMBINATION No Effect 2). Tool built up edge 2). Alarm & lock in machine for tool life excess
REAMER - 1 PLACE Master program verification at Job set up
( A1 -SIDE ) 3). Key lock for un authorised access & Program
6 3 4 72
End User
No Effect
HOLE DEPTH DISTANCE ON Ø11H8
230 L
( 1.30mm MAX )
7 3 4 84
End User
No Effect
SURFACE FINISH ON Ø11H8 4). Preventive maintainance Plan
230 O 8 ( ISCII-TS-MTC-PMP/C-R04 ) 2 5 80
SPECIFICATION
End User
Performance Low
PAGE NO- 46 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

CONCENTRICITY ON Ø11H8 Part get rejected at final inspection
OUT OF
230 T 8 2 6 96
SPECIFICATION
End User
No Effect
100. (23)
POSITION ON Ø15H8 Part get rejected at final inspection
Ø15H8 & Ø11H8 OUT OF
COMBINATION 231 7 2 6 84
SPECIFICATION
REAMER - 1 PLACE ( j | Ø0.80 | E | F-G | G ) Assembly
( A1 -SIDE )
End User
No Effect
CENTER DISTANCE ON Ø15H8 Part get rejected at final inspection
OUT OF
7 2 6 84
107. ( 13.50±0.40mm ).
End User
No Effect
part
End User
THREAD
230 D No Effect
( M14 X 1.00 - 6H )
100. (24) 7 2 6 84
SIZE Assembly
M14 X 1.00 - 6H
TAPPING - 1 PLACE
( A1 -SIDE )
End User
No Effect
CONCENTRICITY ON M14 X 1.00 -
6H OUT OF Part get rejected at final inspection
230 V 7 2 6 84
SPECIFICATION
End User
No Effect
PAGE NO- 47 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

6 3 4 72
No Effect
End User
THREAD DEPTH ON M14 X 1.00 - No Effect

230 I 6H
( x 14.40mm MIN ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
7 3 4 84
100. (24) End User

M14 X 1.00 - 6H
TAPPING - 1 PLACE No Effect
( A1 -SIDE )
POSITION ON M14 X 1.00 - 6H Part get rejected at final inspection
OUT OF
231 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F | G ) Assembly
End User
No Effect
OUT OF
7 2 6 84
113, SPECIFICATION
( 102.00±0.40mm ), Assembly
107.
( 13.50±0.40mm ).
End User
No Effect
6 3 5 90
100. (25) part
502B0059 5.1 (6S
End User
SAE) PORT FORM SPOT FACE DIAMETER
204 L
TOOL ( Ø10.00 & ( Ø25.00(-0.00 to +0.40)mm ) No Effect
Ø9.60 ) - 1 PLACE
( A1 -SIDE ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
DIAMETER
UNDER SIZE
Assembly
End User
No Effect
PAGE NO- 48 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

Caliper
6 3 4 72
End User

204 F
( 1.00mm MAX )
Caliper
End User
No Effect
control for parameter Gauge
DISTANCE UNDER Part get rejected at final inspection 4). Key lock for un authorised access & Program
6 4). Wrong Tool offset 3 4 72
100. (25) Fitment problem not mating with mating part
502B0059 5.1 (6S
End User
SAE) PORT FORM
TOOL ( Ø10.00 & SPOT FACE DISTANCE ON Ø25.00 No Effect
Ø9.60 ) - 1 PLACE 67 FACE
( A1 -SIDE ) ( 147.40±0.50mm ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
Gauge
End User
No Effect
End User
Performance Low
OUT OF
204 R 7 2 6 84
SPECIFICATION
Assembly
( b | 0.10 | A )
End User
No Effect
PAGE NO- 49 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

paste
6 2 4 48
SPECIFICATION
Assembly
End User
No Effect
204 A
( -0.10
-0.30 )
paste
MISSING
Assembly
End User
No Effect
Caliper
6 3 4 72

100. (25)
502B0059 5.1 (6S End User
SAE) PORT FORM
TOOL ( Ø10.00 & 204 C
( 17.00(-0.00 to +1.00)mm )
Ø9.60 ) - 1 PLACE
Caliper
SIZE
End User
No Effect
paste
SPECIFICATION
Assembly
End User

204 E
( 2.50(-0.00 to +0.40)mm )
paste
Assembly
End User
No Effect
PAGE NO- 50 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

paste

OUT OF
6 2 4 48
SPECIFICATION
Assembly
End User
NOSE RADIUS ON Ø15.60

204 I No Effect
( R0.20±0.10mm )
paste

Assembly
End User
No Effect
part
100. (25)
502B0059 5.1 (6S End User
SAE) PORT FORM HOLE DIAMETER ON 9/16 - 18 UNF
No Effect
TOOL ( Ø10.00 & 204 H ( Ø14.30mm Approx )
( Ø12.80±0.10mm ). Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
Ø9.60 ) - 1 PLACE
( A1 -SIDE ) No Effect 2). Tool wear out 2). Alarm & lock in machine for tool life excess Master program verification at Job set up and 5
UNDER SIZE
End User
No Effect
paste
204 G 6 2 4 48
Assembly
End User
No Effect
OUT OF
204 M 7 2 6 84
SPECIFICATION
Assembly
( h | 0.10 | A )
End User
No Effect
PAGE NO- 51 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

moulded paste
6 2 4 48
SPECIFICATION
Assembly
End User
204 K
( Ø15.60(-0.00 to +0.13)mm )
moulded paste
PORT 'C' BORE
MISSING
Assembly
End User
No Effect
SPECIFICATION
Assembly
( 1.60 Rz 16 )
End User
100. (25)
502B0059 5.1 (6S Performance Low
SAE) PORT FORM
TOOL ( Ø10.00 & Next Operation 1). Tool wear out (Life excess) 1). Alarm & lock in machine for tool life excess
Ø9.60 ) - 1 PLACE Master program verification at Job set up
( A1 -SIDE ) No Effect 2). Wrong Tool selection inspection with Profile Projector with moulded
paste
PORT 'C' BORE ANGLE ON Ø15.60 OUT OF Part get rejected at final inspection
204 O 6 2 4 48
Assembly
End User
No Effect
OUT OF
204 P 7 2 6 84
SPECIFICATION
Assembly
( r | Ø0.30 | A )
End User
No Effect
paste
Assembly
End User
No Effect
PAGE NO- 52 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

POSITION ON 6 SAE, 9/16-18 UN
OUT OF
205 7 2 6 84
SPECIFICATION
Assembly
( j | Ø0.80 | E | F-G | G )
100. (25) End User

502B0059 5.1 (6S
No Effect
SAE) PORT FORM
TOOL ( Ø10.00 & 1). Key lock for un authorised access & Program
Ø9.60 ) - 1 PLACE control for parameter Master program verification at Job set up
( A1 -SIDE ) 2). Key lock for un authorised access & Program inspection with CMM
CENTER DISTANCE ON 6 SAE, 9/16- ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
18 UN PORT Part get rejected at final inspection
OUT OF
7 2 6 84
SPECIFICATION
114, ( 113.40±0.40mm ), Assembly
104. ( 37.00±0.40mm ).
End User
No Effect
6 2 6 72
part
End User
THREAD No Effect
204 J
( 9/16 - 18 UNF ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
THREAD UNDER
Assembly 7 2 6 84
SIZE
End User
No Effect
100. (26)
9/16 - 18 UNF No Effect 2). Tap built up edge 2). Alarm & lock in machine for tool life excess
TAPPING - 1 PLACE Master program verification at Job set up and 5
( B1 -SIDE ) 3). Key lock for un authorised access & Program
6 3 4 72
No Effect
End User

204 D
( x 12.70mm MIN )
7 3 4 84
End User
No Effect
PAGE NO- 53 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

POSITION ON 9/16 - 18 UNF Part get rejected at final inspection
OUT OF
205 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
100. (26)
No Effect
9/16 - 18 UNF
TAPPING - 1 PLACE 1). Key lock for un authorised access & Program
( B1 -SIDE ) control for parameter Master program verification at Job set up
CENTER DISTANCE ON 9/16 - 18 ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
UNF Part get rejected at final inspection
OUT OF
7 2 6 84
SPECIFICATION
114, ( 113.40±0.50mm ), Assembly
104. ( 37.00±0.50mm ).
End User
No Effect
part
End User
HOLE DIAMETER
201 No Effect
( Ø5.00±0.50mm )
7 3 4 84
UNDER SIZE Assembly
End User
No Effect
100.(27)
Ø5.00MM DRILLING -
1 PLACE
Caliper
6 3 4 72
End User

202
( x113.00±0.50mm )
Caliper
7 3 4 84
End User
No Effect
PAGE NO- 54 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

OUT OF
203 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
100.(27)
No Effect
Ø5.00MM DRILLING -
1 PLACE 1). Key lock for un authorised access & Program
( A1 -SIDE ) control for parameter Master program verification at Job set up
OUT OF
7 2 6 84
Assembly
105. ( 33.00±0.40mm ).
End User
No Effect
Part get rejected at final inspection 4). Tool worn out Preventive maintainance Record (ISCII-TS-MTC-
DIAMETER OVER ( ISCII-TS-MTC-PMP/C-R04 )
6 5). Preventive maintainance Plan 3 PMP-R05) with CMK study 5 90
SIZE Assembly 5). Machine axis variation (machine wear)
part
End User

206
( Ø6.50±0.50mm )
Subsequent Operation 3). Wrong Tool selection Caliper
7 3 4 84
UNDER SIZE Assembly
End User
No Effect
100.(28)
Ø6.50MM DRILLING -
1 PLACE
Caliper
6 3 4 72
End User

207
( x133.00±0.50mm )
Caliper
7 3 4 84
End User
No Effect
PAGE NO- 55 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

OUT OF
209 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
110.(28)
No Effect
Ø6.50MM DRILLING -
1 PLACE 1). Key lock for un authorised access & Program
OUT OF
7 2 6 84
Assembly
103. ( 49.00±0.50mm ).
End User
No Effect
inspection with CMM
part
End User
100.(29)
Ø13.00MM DRILLING HOLE DIAMETER No Effect
208 L
- 1 PLACE ( Ø13.00mm MAX )
( A1 -SIDE )
7 3 4 84
UNDER SIZE Assembly
End User
No Effect
OUT OF
209 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
100.(29) No Effect
Ø13.00MM DRILLING 1). Key lock for un authorised access & Program
- 1 PLACE Next Operation 1). Program change

OUT OF
Assembly 7 2 6 84
103. ( 49.00±0.50mm ).
End User
No Effect
PAGE NO- 56 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN


caliper

6 3 5 90
SIZE PMP-R05) with CMK study

part
End User
No Effect
SPOT FACE DIAMETER
208 A
( Ø30.00mm MIN )

DIAMETER
7 3 4 84
UNDER SIZE
Assembly
End User
100. (30)
SDC 08 -03 PORT No Effect
FORM TOOL
( Ø15.87 & Ø14.27 ) -
( A1 -SIDE )

Caliper
6 3 4 72
SIZE
End User
No Effect
208 R
( x1.00±0.50mm )

Caliper
7 3 4 84
SIZE
End User
No Effect
PAGE NO- 57 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

Gauge
6 3 4 72
End User

67 Ø30.00
Gauge
End User
No Effect
208 Q 6 ( ISCII-TS-MTC-PMP/C-R04 ) 2 4 48
SPECIFICATION
( 3.20 )
Assembly

100. (30)
End User
SDC 08 -03 PORT
FORM TOOL Performance Low
( Ø15.87 & Ø14.27 ) -
1 PLACE Next Operation 1). Program change
( A1 -SIDE )
CONCENTRICITY Part get rejected at final inspection
OUT OF
208 J 7 2 6 84
SPECIFICATION
( r | Ø0.05 ) Assembly
End User
No Effect
PERPENDICULARITY Part get rejected at final inspection
OUT OF
208 K 7 2 6 84
SPECIFICATION
( b | 0.025 ) Assembly
End User
No Effect
ON Ø20.60 OUT OF 4). Preventive maintainance Plan
208 X Part get rejected at final inspection 6 4). Machine axis variation (machine wear) 2 4 48
( 1.60 ) Assembly
End User
Performance Low
PAGE NO- 58 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

moulded paste
208 W 6 2 4 48
Assembly
End User
No Effect
paste
208 Z 6 2 4 48
Assembly
End User
No Effect
moulded paste
6 2 4 48
SPECIFICATION
Assembly
End User
100. (30) PORT 'C' BORE DIAMETER
SDC 08 -03 PORT No Effect
208 V
FORM TOOL
( Ø15.87 & Ø14.27 ) - ( Ø20.60(-0.00 to +0.12)mm ) Next Operation 1). Tool wear out (Life excess) 1). Alarm & lock in machine for tool life excess
1 PLACE Master program verification at Job set up
( A1 -SIDE ) No Effect 2). Wrong Tool selection inspection with CMM (or) Profile Projector with
moulded paste
CHAMFER DIA Part get rejected at final inspection 6 2 5 60
MISSING
Assembly
End User
No Effect
paste
6 2 4 48
SPECIFICATION
Assembly
End User

208 A
( 2.50(-0.00 to +0.40)mm ) Master program verification at Job set up
paste
CHAMFER Part get rejected at final inspection

6 2 5 60
MISSING
Assembly
End User
No Effect
PAGE NO- 59 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

paste
6 2 4 48
SPECIFICATION
Assembly
End User
No Effect
208 Y
( R0.15±0.10mm ) Next Operation 1). Tool wear out (Life excess) 1). Alarm & lock in machine for tool life excess
paste

Assembly
End User
No Effect
Nos once periodic inspection & 100% Process
Inspection with Air Plug Gauge (or) Plug Gauge &
3). Key lock for un authorised access & Program 4 Nos per Shift Xbar R Chart inspected
part
End User
100. (30) HOLE DIAMETER No Effect
SDC 08 -03 PORT 208 T
( Ø15.88(-0.00 to +0.03)mm )
FORM TOOL Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
( Ø15.87 & Ø14.27 ) - Master program verification at Job set up and 5
1 PLACE Nos once periodic inspection & 100% Process
( A1 -SIDE ) 3). Key lock for un authorised access & Program Inspection with Air Plug Gauge (or) Plug Gauge &
control for parameter 4 Nos per Shift Xbar R Chart inspected
7 3 4 84
UNDER SIZE Assembly
End User
No Effect
6 3 4 72
End User
No Effect
208 N
( 33.24(-0.00 to +0.40)mm )
7 3 4 84
End User
No Effect
PAGE NO- 60 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

SURFACE FINISH ON Ø15.87 4). Preventive maintainance Plan
SPECIFICATION
( 1.60 )
Assembly
End User
Performance Low
part
End User

208 S
( Ø14.28(-0.00 to +0.03)mm )
3). Key lock for un authorised access & Program Inspection with Air Plug Gauge (or) Plug Gauge &
7 3 4 84
UNDER SIZE Assembly
End User
No Effect
100. (30)
SDC 08 -03 PORT
FORM TOOL No Effect 2). Tool built up edge 2). Alarm & lock in machine for tool life excess
( Ø15.87 & Ø14.27 ) - Master program verification at Job set up and 5
1 PLACE Subsequent Operation 3). Wrong Tool selection Nos once periodic inspection with Digital Vernier
( A1 -SIDE ) Caliper (or) Profile Projector with moulded paste
6 3 4 72
End User
No Effect
208 M
( 46.26mm MIN )
7 3 4 84
End User
No Effect
SURFACE FINISH ON Ø14.27 Part get rejected at final inspection 4). Machine axis variation (machine wear)
208 C 6 2 4 48
( 1.60 )
End User
Performance Low
PAGE NO- 61 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

6 3 4 72
End User
HOLE DEPTH ON 3/4-16 UNF -2B No Effect

208 O TAP
( 19.05(-0.00 to +0.40)mm ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
7 3 4 84

100. (30)
SDC 08 -03 PORT End User
FORM TOOL
( Ø15.87 & Ø14.27 ) - No Effect
1 PLACE
( A1 -SIDE ) Next Operation 1). Program change
OUT OF
209 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
No Effect
OUT OF
7 2 6 84
Assembly
103. ( 49.00±0.50mm ).
End User
No Effect
part
100. (31)
3/4 - 16 UNF - 2B End User
THREAD
TAPPING - 1 PLACE 208 U No Effect
( 3/4 - 16 UNF - 2B )
( DATUM "E"
7 2 6 84
SIZE Assembly
End User
No Effect
PAGE NO- 62 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

6 3 4 72
No Effect
End User
THREAD DEPTH ON 3/4 - 16 UNF - No Effect

208 P 2B
7 3 4 84
100. (31) End User

3/4 - 16 UNF - 2B
( DATUM "E"
POSITION ON 3/4 - 16 UNF - 2B Part get rejected at final inspection
OUT OF
209 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
No Effect
UNF - 2B Part get rejected at final inspection
OUT OF
7 2 6 84
SPECIFICATION
111, ( 51.60±0.50mm ), Assembly
103. ( 49.00±0.50mm ).
End User
No Effect
Master program verification at Job set up and
No Effect 2). Tool built up edge 2). Alarm & lock in machine for tool life excess Shift once periodic inspection with CMM (or) Plug
DIAMETER OVER Part get rejected at final inspection 4). Tool worn out Preventive maintainance Record (ISCII-TS-MTC-
6 ( ISCII-TS-MTC-PMP/C-R04 ) 3 5 90
part
100. (32) End User
IES 0111 (8SF SAE,
3/4 - 16 UNF) PORT HOLE DIAMETER No Effect
212 D
FORM TOOL - 1 ( Ø17.00mm MAX )
PLACE
( A1 -SIDE ) No Effect 2). Tool wear out 2). Alarm & lock in machine for tool life excess Master program verification at Job set up and
Shift once periodic inspection with CMM (or) Plug
7 3 4 84
UNDER SIZE
Assembly
End User
No Effect
PAGE NO- 63 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

part
End User
HOLE DIAMETER ON 3/4 - 16 UNF No Effect

212 E
( Ø17.50±0.10mm REF )
7 3 4 84
UNDER SIZE
Assembly
End User
No Effect
End User

212 G
( x 18.00±1.00mm )
100. (32) Subsequent Operation 3). Wrong Tool selection Nos once periodic inspection with Digital Vernier
IES 0111 (8SF SAE, 4). Key lock for un authorised access & Program Caliper
3/4 - 16 UNF) PORT DEPTH UNDER Part get rejected at final inspection 4). Wrong Tool offset
FORM TOOL - 1 SIZE 5). Key lock for un authorised access & Program
PLACE control for parameter
( A1 -SIDE ) Fitment problem not mating with mating part
End User
No Effect
part
End User
SPOT FACE DIAMETER ON 3/4 - 16 No Effect
212 A UNF
7 3 4 84
UNDER SIZE
Assembly
End User
No Effect
HOLE DEPTH ON Ø23.70 DEPTH OVER Part get rejected at final inspection 4). Wrong Tool offset
212 I 6 control for parameter 3 4 72
( x2.40mm MAX ) SIZE 5). Key lock for un authorised access & Program
End User
No Effect
PAGE NO- 64 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

HOLE DEPTH ON Ø23.70 DEPTH UNDER Part get rejected at final inspection 4). Wrong Tool offset
212 I 7 control for parameter 3 4 84
( x2.40mm MAX ) SIZE 5). Key lock for un authorised access & Program
End User
No Effect
6 3 4 72
End User
96 FACE
End User
No Effect
100. (32) Subsequent Operation 3). Wrong offset
IES 0111 (8SF SAE, SURFACE FINISH ON Ø23.70 FACE 4). Preventive maintainance Plan
3/4 - 16 UNF) PORT OUT OF Part get rejected at final inspection 4). Machine axis variation (machine wear)
212 M 6 ( ISCII-TS-MTC-PMP/C-R04 ) 2 4 48
FORM TOOL - 1 SPECIFICATION
Assembly
PLACE ( 3.20 )
( A1 -SIDE ) Customer dissatisfaction at assembly
End User
Performance Low
Next Operation 1). Program change Master program verification at Job set up
RUNOUT ON Ø23.70 FACE
212 H 7 2 6 84
SPECIFICATION
( h | 0.10 | A ) Assembly
End User
No Effect
3). Key lock for un authorised access & Program moulded paste
6 2 4 48
SPECIFICATION
Assembly
End User
PORT 'C' BORE DIAMETER ON 3/4 - No Effect
212 C 16 UNF
( Ø20.60(-0.00 to +0.10)mm ) Next Operation 1). Tool wear out (Life excess) 1). Alarm & lock in machine for tool life excess
PORT 'C' BORE Part get rejected at final inspection
6 2 5 60
MISSING
Assembly
End User
No Effect
PAGE NO- 65 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

3). Key lock for un authorised access & Program paste
6 2 4 48
SPECIFICATION
Assembly
End User

212 N
( 2.50(-0.00 to +0.40)mm )
Assembly
End User
No Effect
CONCENTRICITY ON Ø20.60
212 B 7 2 6 84
SPECIFICATION
( r | Ø0..30 | A ) Assembly
End User
No Effect
100. (32) Subsequent Operation 3). Wrong offset
IES 0111 (8SF SAE,
3/4 - 16 UNF) PORT PORT 'C' BORE ANGLE ON Ø20.60 OUT OF Part get rejected at final inspection
212 P 6 2 4 48
FORM TOOL - 1 ( 15°±1° ) SPECIFICATION
Assembly
PLACE
End User
No Effect
PORT 'C' BORE RUNOUT ON ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
Ø20.60 OUT OF Part get rejected at final inspection
212 J 7 2 6 84
SPECIFICATION
Assembly
( h | 0.10 | A )
End User
No Effect
212 K 6 ( ISCII-TS-MTC-PMP/C-R04 ) 2 4 48
SPECIFICATION
Assembly
( 3.20 )
End User
Performance Low
NOSE RADIUS ON Ø20.60 OUT OF Part get rejected at final inspection
212 L 6 2 4 48
( R0.13 to R0.25mm ) SPECIFICATION
Assembly
End User
No Effect
PAGE NO- 66 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

NOSE RADIUS ON Ø20.60 Part get rejected at final inspection
212 L RADIUS MISSING 6 2 5 60
( R0.13 to R0.25mm )
Assembly
End User
No Effect
ANGLE ON Ø20.60 BOTTOM AREA OUT OF Part get rejected at final inspection
212 O 6 2 4 48
Assembly
100. (32) End User

IES 0111 (8SF SAE,
3/4 - 16 UNF) PORT No Effect
FORM TOOL - 1 1). Key lock for un authorised access & Program
Next Operation 1). Program change Master program verification at Job set up and
PLACE control for parameter
( A1 -SIDE ) 2). Key lock for un authorised access & Program Shift once periodic inspection with CMM
POSITION ON 8 SF, 3/4 - 16 UNF ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
PORT OUT OF Part get rejected at final inspection
213 7 2 6 84
SPECIFICATION
Assembly
( j | Ø0.80 | E | F-G | G )
End User
No Effect
CENTER DISTANCE ON 8 SF, 3/4 - ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
16 UNF PORT Part get rejected at final inspection
OUT OF
7 2 6 84
SPECIFICATION
57, ( 32.00±0.40mm ), Assembly
----. ( 0.00±0.40mm ).
End User
No Effect
part
THREAD End User
212
( 3/4 - 16 UNF )
No Effect
100. (33) Subsequent Operation 3). Wrong Tool selection Inspection with Thread Plug Gauge
3/4 - 16 UNF THREAD UNDER
TAPPING - 1 PLACE Part get rejected at final inspection 7 2 6 84
SIZE
( A1 -SIDE ) Assembly
End User
No Effect
control for parameter Nos once periodic inspection for Digital vernier
4). Key lock for un authorised access & Program caliper with Thread Plug Gauge
THREAD DEPTH ON 3/4 - 16 UNF Part get rejected at final inspection 4). Wrong Tool offset
212 F 6 3 4 72
( x 14.30mm MIN ) SIZE 5). Key lock for un authorised access & Program
No Effect
End User
No Effect
PAGE NO- 67 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

POSITION ON 3/4 - 16 UNF
OUT OF
213 7 2 6 84
SPECIFICATION
Assembly
( j | Ø0.80 | E | F-G | G )
End User
100. (33)
No Effect
3/4 - 16 UNF
OUT OF
7 2 6 84
SPECIFICATION
57, ( 32.00±0.40mm ), Assembly
---. ( 0.00±0.40mm ).
End User
No Effect
6 3 5 90
part
End User
No Effect
HOLE DIAMETER
214
( Ø8.00±0.50mm ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
No Effect 2). Tool wear out 2). Alarm & lock in machine for tool life excess Master program verification at Job set up and
3). Key lock for un authorised access & Program Shift once periodic inspection with CMM (or) Plug
DIAMETER
Assembly 7 3 4 84
UNDER SIZE
End User
100. (34) No Effect

Ø8.00MM DRILLING -
( A1 -SIDE )
Caliper
End User
215
( x80.00±0.50mm )
End User
No Effect
PAGE NO- 68 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

POSITION ON Ø8.00
OUT OF
219 7 2 6 84
SPECIFICATION
Assembly
( j | Ø0.80 | E | F-G | G )
End User
100. (34)
1 PLACE
7 2 6 84
107. ( 13.50±0.40mm ). Assembly
End User
No Effect
6 3 5 90
part
End User
No Effect
HOLE DIAMETER
216
DIAMETER
Assembly 7 3 4 84
UNDER SIZE
End User
No Effect
100. (35)
Ø12.00MM DRILLING
- 1 PLACE
( A1 -SIDE )
Caliper
End User
No Effect
217
( x24.00±0.50mm ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
DISTANCE OVER
End User
No Effect
PAGE NO- 69 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

POSITION ON Ø12.00
OUT OF
219 7 2 6 84
SPECIFICATION
Assembly
( j | Ø0.80 | E | F-G | G )
End User
100. (35)
Ø12.00MM DRILLING No Effect
- 1 PLACE
7 2 6 84
107. ( 13.50±0.40mm ). Assembly
End User
No Effect
6 3 5 90
part
End User
SPOT FACE DIAMETER
218 L
( Ø25.00(-0.00 to +0.40)mm ) No Effect
DIAMETER
UNDER SIZE
Assembly
End User
No Effect
100. (36)
502B0059 5.1 (6S
SAE) PORT FORM
TOOL ( Ø10.00 & Master program verification at Job set up and 5
Ø9.60 ) - 1 PLACE Subsequent Operation 3). Wrong Tool selection Nos once periodic inspection with Digital Vernier
( A1 -SIDE ) Caliper
6 3 4 72
End User
No Effect
218 F
( 1.00mm MAX ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
Caliper
7 3 4 84
End User
No Effect
PAGE NO- 70 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

End User
67 FACE
Gauge
End User
No Effect
End User
Performance Low
100. (36) Next Operation 1). Program change
502B0059 5.1 (6S
SAE) PORT FORM No Effect 2). Wrong work offset
TOOL ( Ø10.00 &
Ø9.60 ) - 1 PLACE Subsequent Operation 3). Machine axis variation (machine wear)
( A1 -SIDE ) PERPENDICULARITY ON Ø25.00
OUT OF
218 R 7 2 6 84
SPECIFICATION
Assembly
( b | 0.10 | A )
End User
No Effect
paste
6 2 4 48
SPECIFICATION
Assembly
End User
CHAMFER HEIGHT ON Ø15.60 No Effect
218 A Next Operation 1). Tool wear out (Life excess) 1). Alarm & lock in machine for tool life excess
( -0.10 Master program verification at Job set up
-0.30 ) No Effect 2). Wrong Tool selection inspection with Profile Projector with moulded
paste

CHAMFER
6 2 5 60
MISSING
Assembly
End User
No Effect
PAGE NO- 71 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

Caliper
6 3 4 72
End User

218 C
( 17.00(-0.00 to +1.00)mm )
Caliper
SIZE
End User
No Effect
paste
SPECIFICATION
Assembly

100. (36)
502B0059 5.1 (6S End User
SAE) PORT FORM
TOOL ( Ø10.00 & PORT 'C' BORE DEPTH ON Ø15.60 No Effect
218 E
Ø9.60 ) - 1 PLACE ( 2.50(-0.00 to +0.40)mm )
( A1 -SIDE ) Next Operation 1). Tool wear out (Life excess) 1). Alarm & lock in machine for tool life excess
paste
Assembly
End User
No Effect
paste

6 2 4 48
SPECIFICATION
Assembly
End User
218 I No Effect
( R0.20±0.10mm )
paste
Assembly
End User
No Effect
PAGE NO- 72 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

part
End User
No Effect
218 H ( Ø14.30mm Approx )
( Ø12.80±0.10mm ). Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
UNDER SIZE
End User
No Effect
paste
218 G 6 2 4 48
Assembly
End User
No Effect
100. (36)
502B0059 5.1 (6S Next Operation 1). Program change
SAE) PORT FORM
TOOL ( Ø10.00 & No Effect 2). Wrong work offset
Ø9.60 ) - 1 PLACE
( A1 -SIDE ) Subsequent Operation 3). Machine axis variation (machine wear)
OUT OF
218 M 7 2 6 84
SPECIFICATION
Assembly
( h | 0.10 | A )
End User
No Effect
moulded paste
6 2 4 48
SPECIFICATION
Assembly
End User
No Effect
218 K Next Operation 1). Tool wear out (Life excess) 1). Alarm & lock in machine for tool life excess
( Ø15.60(-0.00 to +0.13)mm )
moulded paste

PORT 'C' BORE
6 2 5 60
MISSING
Assembly
End User
No Effect
PAGE NO- 73 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

SPECIFICATION
Assembly
( 1.60 Rz 16 )
End User
Performance Low
paste
218 O 6 2 4 48
Assembly
End User
No Effect
OUT OF
218 P 7 2 6 84
SPECIFICATION
Assembly
( r | Ø0.30 | A )
100. (36) End User

502B0059 5.1 (6S
TOOL ( Ø10.00 &
Ø9.60 ) - 1 PLACE
( A1 -SIDE )
paste
Assembly
End User
No Effect
POSITION ON 6 SAE, 9/16-18 UN ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
219 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
No Effect
CENTER DISTANCE ON 6 SAE, 9/16- ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
18 UN PORT Part get rejected at final inspection
OUT OF
7 2 6 84
SPECIFICATION
107, ( 13.50±0.40mm ), Assembly
101. ( 21.00±0.40mm ).
End User
No Effect
PAGE NO- 74 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

6 2 6 72
part
End User
THREAD No Effect
218 J
( 9/16 - 18 UNF ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
THREAD UNDER
Assembly 7 2 6 84
SIZE
End User
No Effect
6 3 4 72
No Effect
End User

218 D
100. (37) ( x 12.70mm MIN )
9/16 - 18 UNF
TAPPING - 1 PLACE
( A1 -SIDE ) No Effect 2). Tap wear out 2). Alarm & lock in machine for tool life excess
7 3 4 84
End User
No Effect
OUT OF
219 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
No Effect
OUT OF
7 2 6 84
SPECIFICATION
107, ( 13.50±0.40mm ), Assembly
104. ( 21.00±0.40mm ).
End User
No Effect
PAGE NO- 75 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

6 3 5 90
part
End User
No Effect 8
HOLE DIAMETER
225 B
DIAMETER
Assembly 7 3 4 84
UNDER SIZE
End User
No Effect

OUT OF
225 C. 7 2 6 84
SPECIFICATION
Assembly
( e | 0.05 )
End User
100. (38) No Effect

Ø5.00MM DRILLING -
( A1 -SIDE )
6 3 4 72
SIZE
HOLE DEPTH ON Ø5.00 End User

225 E.
( x7.00±0.50mm )
No Effect
control for parameter Caliper (or) Depth Gauge
End User
No Effect
tester
Part get rejected at final inspection 4). Machine axis variation (machine wear)
225 D. 6 2 5 60
SPECIFICATION
Assembly
(2 X Rz 7 to 30 )
End User
Performance Low
PAGE NO- 76 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

6 3 5 90
part
225 F.
( Ø5.00±0.10mm )
No Effect
DIAMETER
7 3 4 84
Assembly
End User
No Effect
Caliper
6 3 4 72
End User

226
( x108.00±0.50mm ).
100. (38)
Ø5.00MM DRILLING -
1 PLACE No Effect 2). Tool wear out 2). Alarm & lock in machine for tool life excess
Caliper
7 3 4 84
End User
No Effect
POSITION ON Ø5.00
OUT OF
227 7 2 6 84
SPECIFICATION
Assembly
( j | Ø0.80 | E | F-G | G )
End User
No Effect
OUT OF
7 2 6 84
112. ( 56.00±0.40mm ).
End User
No Effect
PAGE NO- 77 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

6 3 5 90
part
End User
221 B
( Ø5.00(-0.00 to +0.10)mm )
8

7 3 4 84
UNDER SIZE Assembly
End User
No Effect
OUT OF
221 C. 7 2 6 84
SPECIFICATION
Assembly
( e | 0.05 )
End User
No Effect
100. (38)
Ø5.00MM DRILLING - Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
1 PLACE
( A1 -SIDE ) No Effect 2). Tool built up edge 2). Alarm & lock in machine for tool life excess
6 3 4 72
SIZE

221 E.
End User
No Effect
tester
221 D. 6 2 5 60
SPECIFICATION
Assembly
(2 X Rz 7 to 30 )
End User
Performance Low
PAGE NO- 78 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

6 3 5 90
part
221 F.
( Ø5.00±0.10mm )
No Effect
DIAMETER
7 3 4 84
Assembly
End User
No Effect
Caliper
6 3 4 72
End User

222
( x31.50±0.50mm ).
100. (38)
Ø5.00MM DRILLING -
Caliper
7 3 4 84
End User
No Effect
POSITION ON Ø5.00
OUT OF
223 7 2 6 84
SPECIFICATION
Assembly
( j | Ø0.80 | E | F-G | G )
End User
No Effect
OUT OF
7 2 6 84
110. ( 46.00±0.40mm ).
End User
No Effect
PAGE NO- 79 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

part
End User
SPOT FACE DIAMETER
224 No Effect
( vØ10.00±0.50mm )
7 3 4 84
UNDER SIZE
Assembly
End User
No Effect
Height Gauge
6 3 4 72
No Effect
End User
100. (39) SPOT FACE DEPTH DISTANCE ON No Effect

Ø10.00MM END 67 Ø10.00
MILLING - 1 PLACE ( 147.40±0.50mm ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
( A1 -SIDE )
Possibility for tap broken 2). Tool wear out 2). Alarm & lock in machine for tool life excess
Height Gauge
7 3 4 84
End User
No Effect
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
No Effect

OUT OF
7 2 6 84
112. ( 56.00±0.50mm ).
End User
No Effect
PAGE NO- 80 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

part
End User
SPOT FACE DIAMETER
220 No Effect
( vØ10.00±0.50mm )
7 3 4 84
UNDER SIZE
Assembly
End User
No Effect
Height Gauge
6 3 4 72
No Effect
End User
100. (39) SPOT FACE DEPTH DISTANCE ON No Effect

Ø10.00MM END 67 Ø10.00
MILLING - 1 PLACE ( 147.40±0.50mm ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
( A1 -SIDE )
Height Gauge
7 3 4 84
End User
No Effect
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
No Effect

OUT OF
7 2 6 84
110. ( 46.00±0.50mm ).
End User
No Effect
PAGE NO- 81 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

caliper
6 3 5 90
part
End User
SPOT FACE DIAMETER FOR "CS" & No Effect

--- "LX" PUNCH PURPOSE

DIAMETER
7 3 4 84
UNDER SIZE
Assembly
End User
No Effect
100.(40) control for parameter
Caliper
Ø10.00MM END 4). Key lock for un authorised access & Program
MILLING - 2 PLACES DEPTH OVER control for parameter
6 3 4 72
( FOR "CS" & "LX" SIZE 5). Key lock for un authorised access & Program
PUNCH PURPOSE ) Assembly 5). Wrong work offset
( A1 - SIDE )
End User

--- Ø10.00 FOR "CS" & "LX" PUNCH
( 2 X 147.40±0.50mm ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
Caliper
7 3 4 84
End User
No Effect

CENTER DISTANCE ONØ10.00 ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study

( 8.00±0.25mm ), OUT OF
---- 7 2 6 84
( 55.00±0.25mm ), Assembly
( 12.00±0.25mm ).
End User
No Effect
PAGE NO- 82 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN
FIXTURE INDEX
OPERATION NO :- 10 270°
RAW MATERIAL FROM FOUNDRY TO MACHINE SHOP
6 3 5 90
part
End User
259
( Ø8.00±0.50mm )
7 3 4 84
UNDER SIZE Assembly
End User
No Effect
Caliper
6 3 4 72
End User
100.(41)
Ø8.00MM DRILLING -
260
1 PLACE ( x 44.00±0.50mm )
Caliper
7 3 4 84
End User
No Effect
POSITION ON Ø8.00
262 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
No Effect
141. ( 106.00±0.50mm ). Assembly
End User
No Effect
PAGE NO- 83 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

6 3 5 90
part
End User
SPOT FACE DIAMETER
261 L No Effect
( Ø30.00(-0.00 to +0.40)mm )
7 3 4 84
UNDER SIZE
Assembly
End User
No Effect
Caliper
6 3 4 72
End User
100. (42) No Effect

502B0059 5.1 (8S SPOT FACE DEPTH ON Ø30.00
261 F
SAE) PORT FORM ( 1.50mm MAX ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
TOOL ( Ø30.00 &
Ø17.40 ) - 1 PLACE No Effect 2). Tool wear out 2). Alarm & lock in machine for tool life excess
Caliper
DEPTH UNDER
End User
No Effect
6 3 4 72
End User
65 FACE
End User
No Effect
PAGE NO- 84 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

SPECIFICATION
End User
Performance Low
OUT OF
261 R 7 2 6 84
SPECIFICATION
Assembly
( b | 0.10 | A )
End User
No Effect
OUT OF
261 M 7 2 6 84
SPECIFICATION
Assembly
( h | 0.10 | A )
100. (42) End User

502B0059 5.1 (8S
TOOL ( Ø30.00 &
Ø17.40 ) - 1 PLACE Next Operation 1). Tool wear out (Life excess) 1). Alarm & lock in machine for tool life excess
( A2 -SIDE ) 2). Key lock for un authorised access & Program Master program verification at Job set up
SPECIFICATION
Assembly
( 1.60 Rz 16 )
End User
Performance Low
paste
6 2 4 48
SPECIFICATION
Assembly
End User
No Effect
261 A
( -0.10
-0.30 )
paste
MISSING
Assembly
End User
No Effect
PAGE NO- 85 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

Caliper
SIZE
End User

261 C
( 19.00(-0.00 to +1.00)mm )
7 3 4 84
End User
No Effect
paste
6 2 4 48
SPECIFICATION
Assembly
100. (42) End User

502B0059 5.1 (8S
SAE) PORT FORM PORT 'C' BORE DEPTH ON Ø20.60 No Effect
TOOL ( Ø30.00 & 261 E
( 2.50(-0.00 to +0.40)mm )
Ø17.40 ) - 1 PLACE Next Operation 1). Tool wear out (Life excess) 1). Alarm & lock in machine for tool life excess
paste
Assembly
End User
No Effect
paste
6 2 4 48
SPECIFICATION
Assembly
End User

261 I
( R0.20±0.10mm )
paste
Assembly
End User
No Effect
PAGE NO- 86 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

moulded paste
6 2 4 48
SPECIFICATION
Assembly
End User
261 K
( Ø20.60(-0.00 to +0.13)mm )
moulded paste
PORT 'C' BORE
MISSING
Assembly
End User
No Effect
paste
261 G 6 2 4 48
Assembly
End User
100. (42) No Effect

502B0059 5.1 (8S
SAE) PORT FORM Next Operation 1). Tool wear out (Life excess) 1). Alarm & lock in machine for tool life excess
TOOL ( Ø30.00 & Master program verification at Job set up
Ø17.40 ) - 1 PLACE 2). Key lock for un authorised access & Program
( A2 -SIDE ) control for parameter
paste

261 O 6 2 4 48
Assembly
End User
No Effect
part
End User
No Effect
261 H ( Ø19.10mm Approx ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
( Ø17.40±0.10mm ). No Effect 2). Tool wear out 2). Alarm & lock in machine for tool life excess
control for parameter Digital vernier caliper

DIAMETER
Assembly 7 3 4 84
UNDER SIZE
End User
No Effect
PAGE NO- 87 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

OUT OF
261 P 7 2 6 84
SPECIFICATION
Assembly
( r | Ø0.30 | A )
End User
No Effect
paste

261 Q 6 2 4 48
Assembly

100. (42)
502B0059 5.1 (8S
End User
SAE) PORT FORM
TOOL ( Ø30.00 &
Ø17.40 ) - 1 PLACE No Effect
( A2 -SIDE )
POSITION ON 8S SAE, 3/4 - 16 UNF
OUT OF
262 7 2 6 84
SPECIFICATION
Assembly
( j | Ø0.80 | E | F-G | G )
End User
No Effect
CENTER DISTANCE ON 8S SAE, 3/4 3). Preventive maintainance Plan Preventive maintainance Record (ISCII-TS-MTC-
- 16 UNF PORT ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
SPECIFICATION
149, ( 49.00±0.50mm ),
Assembly
141. ( 106.00±0.50mm ).
End User
No Effect
6 2 6 72
part
100.(43) End User
3/4 - 16 UNF THREAD No Effect
261 J
TAPPING - 1 PLACE ( 3/4 - 16 UNF )
7 2 6 84
SIZE Assembly
End User
No Effect
PAGE NO- 88 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

6 3 4 72
No Effect
End User

261 D
( x 14.30mm MIN )
SIZE
100.(43)
3/4 - 16 UNF End User
TAPPING - 1 PLACE
( A2 -SIDE ) No Effect
POSITION ON 3/4 - 16 UNF
262 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G )
Assembly
End User
No Effect
CENTER DISTANCE ON 9/16-18 UN ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
141. ( 106.00±0.50mm ). Assembly
End User
No Effect
6 3 5 90
part
End User
100.(44) No Effect
Ø5.50MM DRILLING - HOLE DIAMETER
263
1 PLACE ( Ø5.50±0.10mm ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
( A2 -SIDE )
DIAMETER
7 3 4 84
UNDER SIZE Assembly
End User
No Effect
PAGE NO- 89 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

Caliper
6 3 4 72
End User

264
( x 66.00±0.50mm )
Caliper
7 3 4 84
100.(44) End User

Ø5.50MM DRILLING -
1 PLACE No Effect
( A2 -SIDE )
POSITION ON Ø5.50
272 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
No Effect
OUT OF
7 2 6 84
Assembly
146. ( 15.00±0.50mm ).
End User
No Effect
6 3 5 90
part
100.(45) End User
Ø7.00MM DRILLING - HOLE DIAMETER No Effect
265
1 PLACE ( Ø7.00±0.50mm )
7 3 4 84
UNDER SIZE Assembly
End User
No Effect
PAGE NO- 90 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

Caliper
6 3 4 72
End User

266
( x 40.00±0.50mm )
Caliper
7 3 4 84
100.(45) End User

Ø7.00MM DRILLING -
1 PLACE No Effect
( A2 -SIDE )
POSITION ON Ø7.00
272 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
No Effect
OUT OF
7 2 6 84
Assembly
146. ( 15.00±0.50mm ).
End User
No Effect
6 3 5 90
part
100.(46) End User
Ø12.00MM DRILLING HOLE DIAMETER No Effect
267
- 1 PLACE ( Ø12.00±0.50mm )
7 3 4 84
UNDER SIZE Assembly
End User
No Effect
PAGE NO- 91 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

Caliper
6 3 4 72
End User

268
( x 27.00±0.40mm )
Caliper
7 3 4 84
100.(46) End User

Ø12.00MM DRILLING
- 1 PLACE No Effect
( A2 -SIDE )
POSITION ON Ø12.00
272 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G )
Assembly
End User
No Effect
OUT OF
7 2 6 84
Assembly
146. ( 15.00±0.40mm ).
End User
No Effect
part
100. (47) End User
M8 X 1.00 TAPPING - THREAD
269 No Effect
1 PLACE ( M8 X 1.0 )
7 2 6 84
SIZE Assembly
End User
No Effect
PAGE NO- 92 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

6 3 4 72
No Effect
End User
THREAD DEPTH ON M8 X 1.0 No Effect

270
( x 36.00(-0.00 to +2.00)mm )
7 3 4 84
100. (47) End User

M8 x 1.00 TAPPING -
1 PLACE No Effect
( A2 -SIDE )
POSITION ON M8 X 1.00
272 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
No Effect
CENTER DISTANCE ON M8 X 1.00
OUT OF
7 2 6 84
Assembly
146. ( 15.00±0.40mm ).
End User
No Effect
6 3 5 90
100.(48) part
IES 0111 (6SF SAE, End User
9/16 - 18 UNF) PORT
FORM TOOL 271 D
( Ø12.50±0.50mm )
( Ø19.00 & Ø12.50 ) -
1 PLACE
( A2 -SIDE ) No Effect 2). Tool wear out 2). Alarm & lock in machine for tool life excess Master program verification at Job set up and
7 3 4 84
UNDER SIZE Assembly
End User
No Effect
PAGE NO- 93 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

6 3 5 90
part
End User
HOLE DIAMETER ON 9/16 - 18 UNF No Effect
271 E
( Ø12.93±0.10mm )
7 3 4 84
UNDER SIZE Assembly
End User
No Effect
caliper
6 3 4 72
End User
100.(48)
IES 0111 (6SF SAE, HOLE DEPTH ON Ø12.93 No Effect
271 G
9/16 - 18 UNF) PORT ( x 16.00±1.00mm )
( Ø19.00 & Ø12.50 ) -
caliper
7 3 4 84
End User
No Effect
6 3 5 90
part
End User
SPOT FACE DIAMETER ON 9/16 - No Effect

271 A 18 UNF Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
( Ø19.00(-0.00 to +0.40)mm )
DIAMETER
Assembly 7 3 4 84
UNDER SIZE
End User
No Effect
PAGE NO- 94 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

End User

271 I
( x 1.60mm MAX)
End User
No Effect
SPOT FACE Part get rejected at final inspection 4). Wrong Tool offset
DISTANCE OVER 6 control for parameter 3 4 72
100.(48) End User

IES 0111 (6SF SAE,
9/16 - 18 UNF) PORT
87 FACE
( 27.40±0.50mm )
( Ø19.00 & Ø12.50 ) -
( A2 -SIDE )
DISTANCE UNDER 7 control for parameter 3 4 84
End User
No Effect
SPECIFICATION
( 3.20 ) Assembly
End User
Performance Low
RUNOUT ON Ø19.00 FACE Part get rejected at final inspection
OUT OF
271 H 7 2 6 84
SPECIFICATION
( h | 0.10 | A ) Assembly
End User
No Effect
PAGE NO- 95 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

OUT OF
271 B 7 2 6 84
SPECIFICATION
( r | Ø0.30 | A ) Assembly
End User
No Effect
271 K 6 ( ISCII-TS-MTC-PMP/C-R04 ) 2 4 48
SPECIFICATION
Assembly
( 3.20 )
End User
Performance Low
moulded paste
6 2 4 48
SPECIFICATION
Assembly

100.(48)
End User
IES 0111 (6SF SAE, PORT 'C' BORE DIAMETER ON 9/16
9/16 - 18 UNF) PORT - 18 UNF
FORM TOOL No Effect
271 C
( Ø19.00 & Ø12.50 ) -
1 PLACE Next Operation 1). Tool wear out (Life excess) 1). Alarm & lock in machine for tool life excess
( Ø15.65(-0.00 to +0.10)mm )
moulded paste
MISSING
Assembly
End User
No Effect
paste
6 2 4 48
SPECIFICATION
Assembly
End User

271 N
( 2.50(-0.00 to +0.40)mm )
paste
Assembly
End User
No Effect
PAGE NO- 96 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

paste
6 2 4 48
SPECIFICATION
Assembly
End User

271 L
( R0.13 to R0.25mm )
paste
Assembly
End User
No Effect
paste
100.(48) Subsequent Operation 3). Wrong offset
IES 0111 (6SF SAE,
9/16 - 18 UNF) PORT Part get rejected at final inspection
FORM TOOL ANGLE ON Ø15.65 BOTTOM AREA OUT OF
271 O 6 2 4 48
( Ø19.00 & Ø12.50 ) - ( 45°±5° ) SPECIFICATION
1 PLACE Assembly
( A2 -SIDE )
End User
No Effect

POSITION ON 6 SF, 9/16 - 18 UNF
OUT OF
272 7 2 6 84
SPECIFICATION
Assembly
( j | Ø0.80 | E | F-G | G )
End User
No Effect
CENTER DISTANCE ON 6 SF, 9/16 - Subsequent Operation 3). Machine axis variation (machine wear)
18 UNF PORT
7 2 6 84
SPECIFICATION
140, ( 15.00±0.40mm ), Assembly
142. ( 85.20±0.40mm ).
End User
No Effect
100. (49) 4). Preventive maintainance Plan
9/16 - 18 UNF THREAD THREAD OVER ( ISCII-TS-MTC-PMP/C-R04 ) Preventive maintainance Record (ISCII-TS-MTC-
271 6 2 6 72
TAPPING - 1 PLACE ( 9/16 - 18 UNF ) SIZE 5). Preventive maintainance Plan PMP-R05) with CMK study
( A2 -SIDE ) ( ISCII-TS-MTC-PMP/C-R04 )
part
End User
No Effect
PAGE NO- 97 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

THREAD THREAD UNDER
271 Assembly 7 2 6 84
( 9/16 - 18 UNF ) SIZE
End User
No Effect
6 3 4 72
No Effect
End User

271 F
( x 12.70mm MIN )
100. (49) 4). Key lock for un authorised access & Program
9/16 - 18 UNF DEPTH UNDER control for parameter
7 3 4 84
TAPPING - 1 PLACE SIZE 5). Key lock for un authorised access & Program
End User
No Effect
OUT OF
272 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
No Effect
OUT OF
7 2 6 84
SPECIFICATION
142, ( 85.20±0.40mm ), Assembly
146. ( 15.00±0.40mm ).
End User
No Effect
100.(50) 4). Preventive maintainance Plan
Ø6.00MM DRILLING - HOLE DIAMETER DIAMETER OVER Part get rejected at final inspection 4). Tool worn out Preventive maintainance Record (ISCII-TS-MTC-
1 PLACE ( Ø6.00±0.50mm ) SIZE 5). Preventive maintainance Plan PMP-R05) with CMK study
( A2 -SIDE ) ( ISCII-TS-MTC-PMP/C-R04 )
part
End User
No Effect
PAGE NO- 98 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

HOLE DIAMETER DIAMETER Part get rejected at final inspection
273 7 3 4 84
( Ø6.00±0.50mm ) UNDER SIZE Assembly
End User
No Effect
caliper
6 3 4 72
End User
No Effect
274
( x 37.50±0.50mm )
caliper
100.(50) 7 3 4 84
Ø6.00MM DRILLING - Assembly 5). Wrong work offset
1 PLACE control for parameter
( A2 -SIDE )
End User
No Effect


OUT OF
276 7 2 6 84
( j | Ø0.80 | E | F-G | G )
End User
No Effect


OUT OF
7 2 6 84
143. ( 60.00±0.40mm ). Assembly
End User
No Effect
PAGE NO- 99 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

No Effect 2). Tool built up edge 2). Alarm & lock in machine for tool life excess Shift once periodic inspection with Digital vernier
6 3 5 90
part
End User
HOLE DIAMETER
275 A ( Ø0.625±0.005 Inch No Effect
(or) Ø15.875±0.127mm )
3). Key lock for un authorised access & Program Shift once periodic inspection with Digital vernier
7 3 4 84
UNDER SIZE Assembly
End User
No Effect
caliper
6 3 4 72
End User
100.(51)
CP4 - 2 CAVITY
PORT FORM TOOL ( 275 H ( x 0.03±0.01 Inch
Ø15.875 & Ø11.112 ) - (or) 0.762±0.254mm ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
1 PLACE
( A2 -SIDE ) No Effect 2). Tool wear out 2). Alarm & lock in machine for tool life excess
caliper
7 3 4 84
End User
No Effect
6 3 5 90
part
End User
HOLE DIAMETER ON 7/16 - 20 UNF -
2B No Effect
----
( Ø0.4375±0.005 Inch Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
(or) Ø11.112±0.10mm )
DIAMETER
7 3 4 84
UNDER SIZE Assembly
End User
No Effect
PAGE NO- 100 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

caliper
6 3 4 72
End User
No Effect
275 S ( x 0.696±0.005 Inch
(or) x17.68±0.12mm ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
caliper
7 3 4 84
End User
No Effect
paste
ANGLE ON Ø0.4375 END AREA OUT OF Part get rejected at final inspection
275 N 6 2 4 48
100.(51) Assembly
CP4 - 2 CAVITY
PORT FORM TOOL ( Customer dissatisfaction at assembly
Ø15.875 & Ø11.112 ) -
1 PLACE End User
( A2 -SIDE )
No Effect
paste
ANGLE ON Ø0.4375 START AREA OUT OF
275 M Part get rejected at final inspection 6 2 4 48
Assembly
End User
No Effect
Caliper (or) Plug Gauge (or) CMM & 4 Nos Per
3). Key lock for un authorised access & Program Shift Xbar R Chart Inspected
8 2 5 80
part
275 D ( Ø0.312 to 0.314 Inch No Effect
(or) Ø7.925 to Ø7.975mm )
3). Key lock for un authorised access & Program Caliper (or) Plug Gauge (or) CMM & 4 Nos Per
control for parameter Shift Xbar R Chart Inspected
DIAMETER Part get rejected at final inspection 8 3 4 96
UNDER SIZE
Assembly
End User
No Effect
PAGE NO- 101 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

End User
No Effect
275 R ( x 1.250±0.005 Inch
(or) 31.475±0.12mm) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
End User
No Effect
OUT OF
275 E 7 2 6 84
SPECIFICATION
( r | Ø0.002 Inch | A ) Assembly
100.(51) End User

CP4 - 2 CAVITY
PORT FORM TOOL ( No Effect
Ø15.875 & Ø11.112 ) -
1 PLACE
( A2 -SIDE ) 2). Key lock for un authorised access & Program Master program verification at Job set up
275 U 8 ( ISCII-TS-MTC-PMP/C-R04 ) 2 4 64
SPECIFICATION
( 63.00 ) Assembly
End User
Performance Low
paste
ANGLE ON Ø0.312 END AREA OUT OF
275 O Part get rejected at final inspection 6 2 4 48
Assembly
End User
No Effect
275 I 6 ( ISCII-TS-MTC-PMP/C-R04 ) 2 4 48
SPECIFICATION
( 125.00 Inch ) Assembly
End User
Performance Low
PAGE NO- 102 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

DISTANCE OVER 6 control for parameter 3 4 72
End User

88 FACE
DISTANCE UNDER 7 control for parameter 3 4 84
End User
No Effect
ANGLE OUT OF Part get rejected at final inspection 4). Machine axis variation (machine wear)
275 W 6 ( ISCII-TS-MTC-PMP/C-R04 ) 2 4 48
SPECIFICATION
( 63 Inch ) Assembly
End User
100.(51)
CP4 - 2 CAVITY Performance Low
PORT FORM TOOL (
Ø15.875 & Ø11.112 ) - 1). Key lock for un authorised access & Program
1 PLACE control for parameter Master program verification at Job set up
OUT OF
275 C 7 2 6 84
SPECIFICATION
( r | Ø0.002 Inch | A ) Assembly
End User
No Effect
moulded paste
6 2 4 48
SPECIFICATION
Assembly
PORT 'C' BORE DIAMETER ON 7/16 End User

- 20 UNF - 2B
No Effect
275 B
( Ø0.487 to Ø492 Inch Next Operation 1). Tool wear out (Life excess) 1). Alarm & lock in machine for tool life excess
(or) Ø12.37 to Ø12.50mm ) Master program verification at Job set up
moulded paste
MISSING
Assembly
End User
No Effect
PAGE NO- 103 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

paste
6 2 4 48
SPECIFICATION
Assembly
End User
No Effect
275 T
( 0.093 to 0.108 Inch
(or) 2.36 to 2.74mm )
paste
Assembly
End User
No Effect
paste
6 2 4 48
SPECIFICATION
Assembly
End User
100.(51)
NOSE RADIUS ON Ø0.487 ANGLE
CP4 - 2 CAVITY No Effect
PORT FORM TOOL ( 275 Q
( R0.005 to R0.010 Inch
Ø15.875 & Ø11.112 ) - Next Operation 1). Tool wear out (Life excess) 1). Alarm & lock in machine for tool life excess
(or) R0.12 to R0.25mm )
1 PLACE Master program verification at Job set up
paste
Assembly
End User
No Effect
paste
PORT 'C' BORE ANGLE ON Ø0.487
OUT OF
275 V Part get rejected at final inspection 6 2 4 48
SPECIFICATION
( 12° to 14° )
Assembly
End User
No Effect
POSITION ON 7/16 - 20 UNF - 2B
OUT OF
276 7 2 6 84
SPECIFICATION
Assembly
( j | Ø0.80 | E | F-G | G )
End User
No Effect
PAGE NO- 104 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

100.(51) 3). Preventive maintainance Plan Preventive maintainance Record (ISCII-TS-MTC-
CENTER DISTANCE ON 7/16 - 20 Subsequent Operation 3). Machine axis variation (machine wear)
CP4 - 2 CAVITY ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
UNF - 2B PORT
PORT FORM TOOL ( OUT OF Part get rejected at final inspection
7 2 6 84
Ø15.875 & Ø11.112 ) - SPECIFICATION
149, ( 49.00±0.40mm ), Assembly
1 PLACE
143. ( 60.00±0.40mm ).
( A2 -SIDE )
End User
No Effect
6 2 6 72
part
End User
THREAD No Effect
275 F
( 7/16 - 20 UNF - 2B ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
THREAD UNDER
Assembly 7 2 6 84
SIZE
End User
No Effect
6 3 4 72
7/16 - 20 UNF - 2B No Effect
TAPPING - 1 PLACE
( A2 -SIDE )
End User
THREAD DEPTH ON 7/16 - 20 UNF -
2B No Effect
275 J ( x 0.45 Inch MIN
(or) x11.43mm MIN )
7 3 4 84
End User
No Effect
PERPENDICULARITY ON 7/16 - 20
UNF - 2B OUT OF
275 G 7 2 6 84
( b | 0.001 Inch | B )
End User
No Effect
PAGE NO- 105 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

POSITION ON 7/16 - 20 UNF - 2B Part get rejected at final inspection
OUT OF
276 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
100. (52)
No Effect
7/16 - 20 UNF - 2B
UNF - 2B Part get rejected at final inspection
OUT OF
7 2 6 84
SPECIFICATION
149, ( 49.00±0.40mm ), Assembly
143. ( 60.00±0.40mm ).
End User
No Effect
6 3 5 90
part
End User
277
( Ø19.00±0.50mm )
7 3 4 84
UNDER SIZE Assembly
End User
No Effect
100.(53)
Ø19.00MM DRILLING
- 1 PLACE
( A2 -SIDE ) No Effect 2). Tool built up edge 2). Alarm & lock in machine for tool life excess
caliper
6 3 4 72
End User

278 No Effect
( x 68.00±0.40mm )
caliper
End User
No Effect
PAGE NO- 106 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

OUT OF
280 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
100.(53)
No Effect
Ø19.00MM DRILLING
- 1 PLACE 1). Key lock for un authorised access & Program
OUT OF
7 2 6 84
Assembly
51. ( 36.00±0.50mm ).
End User
No Effect
6 3 5 90
part
End User
SPOT FACE DIAMETER
279 A. ( Ø1.500±0.005 Inch No Effect
(or) Ø38.10±0.127mm )
7 3 4 84
UNDER SIZE Assembly
End User
100.(54) No Effect
ES - 1339 PORT
FORM TOOL
( Ø19.00 & Ø12.50 ) -
1 PLACE No Effect 2). Tool built up edge 2). Alarm & lock in machine for tool life excess
caliper
6 3 4 72
End User
279 B ( x0.031±0.005 Inch No Effect
(or) 0.787±0.127mm )
caliper
End User
No Effect
PAGE NO- 107 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

No Effect 2). Tool built up edge 2). Alarm & lock in machine for tool life excess Nos once periodic inspection & 100% Process
3). Key lock for un authorised access & Program Inspection with Air Plug Gauge (or) Plug Gauge
6 3 5 90
part
End User
HOLE DIAMETER
279 C ( Ø0.8281 to Ø0.8268 Inch No Effect
(or) Ø21.034 to Ø21.000mm )
Subsequent Operation 3). Wrong Tool selection Inspection with Air Plug Gauge (or) Plug Gauge
7 3 4 84
UNDER SIZE Assembly
End User
No Effect
caliper
6 3 4 72
End User
100.(54)
ES - 1339 PORT 279 D ( x2.446±0.005 Inch No Effect
FORM TOOL (or) x62.12±0.12mm )
( Ø19.00 & Ø12.50 ) - Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
1 PLACE
( A2 -SIDE ) No Effect 2). Tool wear out 2). Alarm & lock in machine for tool life excess
caliper
End User
No Effect
PERPENDICULARITY ON Ø0.8281 Part get rejected at final inspection
OUT OF
279 AC 8 2 6 96
SPECIFICATION
( b | 0.001 Inch | A ) Assembly
End User
No Effect
RUNOUT ON Ø0.8281 Part get rejected at final inspection
OUT OF
279 AD 7 2 6 84
SPECIFICATION
( h | 0.002 Inch | B ) Assembly
End User
No Effect
PAGE NO- 108 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

279 U 8 ( ISCII-TS-MTC-PMP/C-R04 ) 2 4 64
SPECIFICATION
Assembly
( 63 Inch )
End User
Performance Low
8 2 5 80
part
End User
HOLE DIAMETER
279 E ( Ø0.9068 to Ø0.9055 Inch No Effect
(or) Ø23.033 to Ø23.000mm )
3). Key lock for un authorised access & Program Inspection with Air Plug Gauge (or) Plug Gauge &
8 3 4 96
UNDER SIZE Assembly
End User
No Effect
100.(54)
ES - 1339 PORT No Effect 2). Tool built up edge 2). Alarm & lock in machine for tool life excess
FORM TOOL Master program verification at Job set up and 5
( Ø19.00 & Ø12.50 ) - 3). Key lock for un authorised access & Program
1 PLACE control for parameter
caliper
6 3 4 72
End User
279 F ( x2.016±0.005 Inch No Effect
(or) x51.20±0.12mm )
caliper
End User
No Effect

OUT OF
279 AC 8 2 6 96
SPECIFICATION
End User
No Effect
PAGE NO- 109 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

OUT OF
279 AD 7 2 6 84
SPECIFICATION
End User
No Effect
279 V 8 ( ISCII-TS-MTC-PMP/C-R04 ) 2 4 64
SPECIFICATION
Assembly
( 63 Inch )
End User
Performance Low
3). Key lock for un authorised access & Program Inspection with Air Plug Gauge (or) Plug Gauge
6 3 5 90
part
HOLE DIAMETER ON 1-1/16-12 UN- End User
2B No Effect
279 G
100.(54) ( Ø0.978 to Ø0.972 Inch
(or) Ø24.841 to Ø24.688mm ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
ES - 1339 PORT
FORM TOOL No Effect 2). Tool wear out 2). Alarm & lock in machine for tool life excess Master program verification at Job set up and 5
( Ø19.00 & Ø12.50 ) - Nos once periodic inspection & 100% Process
1 PLACE Subsequent Operation 3). Wrong Tool selection Inspection with Air Plug Gauge (or) Plug Gauge
( A2 -SIDE )
7 3 4 84
UNDER SIZE Assembly
End User
No Effect
caliper
6 3 4 72
End User
279 H ( x1.051±0.005 Inch

(or) x26.695±0.12mm )
caliper
DEPTH UNDER
End User
No Effect
PAGE NO- 110 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

OUT OF
279 AC 8 2 6 96
SPECIFICATION
End User
No Effect
OUT OF
279 AD 7 2 6 84
SPECIFICATION
End User
No Effect
6 3 5 90
part
100.(54) End User
ES - 1339 PORT HOLE DIAMETER
FORM TOOL 279 T ( Ø0.796 Inch MAX No Effect
( Ø19.00 & Ø12.50 ) - (or) Ø20.218mm MAX )
1 PLACE
( A2 -SIDE ) No Effect 2). Tool wear out 2). Alarm & lock in machine for tool life excess Master program verification at Job set up and 5
7 3 4 84
UNDER SIZE Assembly
End User
No Effect
caliper
6 3 4 72
End User
279 S ( x2.500 Inch MIN No Effect
(or) x63.50mm MIN )

caliper
End User
No Effect
PAGE NO- 111 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

ANGLE ON Ø0.8281 END AREA OUT OF Part get rejected at final inspection
279 AB 6 2 4 48
Assembly
End User
No Effect
6 2 4 48
SPECIFICATION
Assembly
NOSE RADIUS ON Ø0.9068 END Customer dissatisfaction at assembly

AREA
End User
( R0.062±0.005 Inch )
No Effect
279 AA &
NOSE RADIUS ON Ø0.978 END 2). Key lock for un authorised access & Program
AREA control for parameter
( R0.062±0.005 Inch ) Subsequent Operation 3). Wrong offset
Assembly
End User
No Effect
100.(54) Subsequent Operation 3). Wrong offset
SURFACE FINISH ON Ø0.9068 END control for parameter
ES - 1339 PORT 4). Preventive maintainance Plan
R0.062 AREA Part get rejected at final inspection 4). Machine axis variation (machine wear)
FORM TOOL OUT OF ( ISCII-TS-MTC-PMP/C-R04 )
279 Z 6 2 4 48
( Ø19.00 & Ø12.50 ) - SPECIFICATION
Assembly
1 PLACE
( 63 Inch )
End User
Performance Low
SURFACE FINISH ON Ø0.978 END control for parameter
R0.062 AREA 4). Preventive maintainance Plan
279 Z 6 ( ISCII-TS-MTC-PMP/C-R04 ) 2 4 48
SPECIFICATION
Assembly
( 63 Inch )
End User
Performance Low
279 X 6 ( ISCII-TS-MTC-PMP/C-R04 ) 2 4 48
SPECIFICATION
Assembly
( 100 Inch )
End User
Performance Low
ANGLE ON Ø0.978 START AREA OUT OF Part get rejected at final inspection
279 W 6 2 4 48
Assembly
End User
No Effect
PAGE NO- 112 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

Height Gauge
6 3 4 72
No Effect
End User

74 FACE
Height Gauge
7 3 4 84
End User
No Effect
No Effect 2). Tool built up edge 2). Alarm & lock in machine for tool life excess inspection with CMM (or) Profile Projector with
6 3 5 90
100.(54) Loose Fitment problem not mating with mating
ES - 1339 PORT part
FORM TOOL
End User
( Ø19.00 & Ø12.50 ) - HOLE DIAMETER
1 PLACE 279 K ( Ø1.148 to Ø1.152 Inch No Effect
( A2 -SIDE ) (or) Ø29.16 to Ø29.26mm )
No Effect 2). Tool wear out 2). Alarm & lock in machine for tool life excess Master program verification at Job set up
3). Key lock for un authorised access & Program inspection with CMM (or) Profile Projector with
Subsequent Operation 3). Wrong Tool selection moulded paste
7 3 4 84
UNDER SIZE Assembly
End User
No Effect
279 AC 8 2 6 96
SPECIFICATION
End User
No Effect
OUT OF
279 AD 7 2 6 84
SPECIFICATION
End User
No Effect
PAGE NO- 113 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

6 2 4 48
SPECIFICATION
Assembly
End User

279 Y ( 0.130 to 0.145 Inch
(or) 3.30 to 3.68mm ) Master program verification at Job set up
Assembly
End User
No Effect
279 L 6 2 4 48
( 14° to 16° ) SPECIFICATION
Assembly
End User
No Effect
100.(54) SURFACE FINISH ON Ø1.148 control for parameter
ANGLE 4). Preventive maintainance Plan
ES - 1339 PORT OUT OF Part get rejected at final inspection 4). Machine axis variation (machine wear)
FORM TOOL SPECIFICATION
( Ø19.00 & Ø12.50 ) - Assembly
1 PLACE ( 100 Inch )
( A2 -SIDE )
End User
Performance Low
6 2 4 48
SPECIFICATION
Assembly
End User
NOSE RADIUS ON Ø1.148 ANGLE
279 N ( R0.005 to R0.010 Inch No Effect
(or) R0.12 to R0.25mm ) Next Operation 1). Tool wear out (Life excess) 1). Alarm & lock in machine for tool life excess
Assembly
End User
No Effect
POSITION ON 1-1/16-12 UN - 2B ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
280 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
No Effect
PAGE NO- 114 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

100.(54) ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
CENTER DISTANCE ON 1-1/16-12
ES - 1339 PORT
UN - 2B PORT Part get rejected at final inspection
FORM TOOL OUT OF
7 2 6 84
( Ø19.00 & Ø12.50 ) - 147, SPECIFICATION
( 32.00±0.40mm ), Assembly
1 PLACE 51.
( 36.00±0.50mm ).
( A2 -SIDE )
End User
No Effect
6 2 6 72
part
End User
THREAD No Effect
279 I
( 1-1/16-12 UN - 2B ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
THREAD UNDER
Assembly 7 2 6 84
SIZE
End User
No Effect
6 3 4 72
100. (55) Assembly 5). Wrong work offset
1-1/16-12 UN - 2B
( A2 -SIDE )
End User
THREAD DEPTH ON 1-1/16-12 UN -
2B No Effect
279 J ( x 0.810±0.005 Inch
(or) x20.57±0.12mm )
7 3 4 84
End User
No Effect
2). Key lock for un authorised access & Program once periodic Inspection with CMM
PERPENDICULARITY ON 1-1/16-12
UN - 2B Part get rejected at final inspection
OUT OF
279 AE 7 2 6 84
SPECIFICATION
Assembly
( b | 0.001 Inch | B )
End User
No Effect
PAGE NO- 115 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

2). Key lock for un authorised access & Program once periodic Inspection with CMM
CIRCULARITY ON 1-1/16-12 UN - 2B
(PITCH DIA) Part get rejected at final inspection
OUT OF
279 AF 8 2 6 96
SPECIFICATION
Assembly
( e | 0.0009 Inch )
End User
No Effect
100. (55) POSITION ON 1-1/16-12 UN - 2B Part get rejected at final inspection
1-1/16-12 UN - 2B OUT OF
280 7 2 6 84
TAPPING - 1 PLACE SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
( A2 -SIDE )
End User
No Effect
CENTER DISTANCE ON 1-1/16-12 ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
UN - 2B Part get rejected at final inspection
OUT OF
7 2 6 84
SPECIFICATION
147, ( 32.00±0.40mm ), Assembly
51. ( 36.00±0.50mm ).
End User
No Effect
6 3 5 90
part
End User
No Effect 8
HOLE DIAMETER
282 B
100. (56)
DIAMETER
Ø4.00MM DRILLING - Assembly 7 3 4 84
UNDER SIZE
1 PLACE
( A2 -SIDE ) Tight Fitment problem not mating with mating part
End User
No Effect

OUT OF
282 C. 7 2 6 84
SPECIFICATION
Assembly
( e | 0.05 )
End User
No Effect
PAGE NO- 116 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

6 3 4 72
SIZE

282 E.
End User
No Effect
tester
(2 X Rz 7 to 30 ) Assembly
End User
100. (56)
Ø4.00MM DRILLING - Performance Low
1 PLACE
6 3 5 90
part
End User

282 F.
( Ø4.00±0.10mm )
DIAMETER
7 3 4 84
UNDER SIZE Assembly
End User
No Effect
Caliper
HOLE DEPTH ON Ø4.00 Part get rejected at final inspection 4). Wrong Tool offset
283 6 3 4 72
( x82.00±0.50mm ). SIZE 5). Key lock for un authorised access & Program
End User
No Effect
PAGE NO- 117 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

Caliper
283 7 3 4 84
( x90.00±0.50mm ). SIZE 5). Key lock for un authorised access & Program
End User
No Effect
100. (56) POSITION ON Ø4.00
Ø4.00MM DRILLING - Part get rejected at final inspection
OUT OF
1 PLACE 288 7 2 6 84
SPECIFICATION
Assembly
( A2 -SIDE ) ( j | Ø0.80 | E | F-G | G )
End User
No Effect
OUT OF
7 2 6 84
148. ( 40.20±0.50mm ).
End User
No Effect
6 3 5 90
part
End User
286 B 8
( Ø5.00(-0.00 to +0.10)mm )
100. (57)
Ø5.00MM DRILLING - DIAMETER
7 3 4 84
1 PLACE UNDER SIZE Assembly
( A2 -SIDE )
End User
No Effect
CIRCULARITY ON Ø5.00 ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
286 C. 7 2 6 84
SPECIFICATION
End User
No Effect
PAGE NO- 118 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

6 3 4 72
SIZE

286 E.
End User
No Effect
tester
( Rz 7 to 30 ) Assembly
End User
100. (57)
Ø5.00MM DRILLING - Performance Low
1 PLACE
6 3 5 90
part
286 F.
( Ø5.00±0.10mm )
No Effect
DIAMETER
7 3 4 84
Assembly
End User
No Effect

OUT OF
288 7 2 6 84
SPECIFICATION
Assembly
( j | Ø0.80 | E | F-G | G )
End User
No Effect
PAGE NO- 119 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

Caliper
6 3 4 72
End User

287
( x72.00±0.50mm ).
100. (57) Caliper
Ø5.00MM DRILLING - Part get rejected at final inspection 4). Wrong Tool offset
1 PLACE 7 3 4 84
( A2 -SIDE ) Assembly 5). Wrong work offset
End User
No Effect
OUT OF
7 2 6 84
145. ( 11.00±0.50mm ).
End User
No Effect
part
End User
SPOT FACE DIAMETER
281 No Effect
( vØ10.00±0.50mm )
100. (58) Subsequent Operation 3). Wrong Tool selection caliper
Ø10.00MM END
MILLING - 2 PLACES DIAMETER Part get rejected at final inspection
7 3 4 84
( A2 -SIDE ) UNDER SIZE
Assembly
End User
No Effect
284 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly

End User
No Effect
PAGE NO- 120 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

Height Gauge
6 3 4 72
No Effect
End User

67 Ø10.00
Height Gauge
MILLING - 2 PLACES DEPTH DISTANCE control for parameter
7 3 4 84
( A2 -SIDE ) OVER SIZE 5). Key lock for un authorised access & Program
End User
No Effect
7 2 6 84
148. ( 40.20±0.50mm ). Assembly
End User
No Effect
part
End User
SPOT FACE DIAMETER
185 No Effect
( vØ10.00±0.50mm )
100. (58) Subsequent Operation 3). Wrong Tool selection caliper
Ø10.00MM END
MILLING - 2 PLACES DIAMETER Part get rejected at final inspection
7 3 4 84
( A2 -SIDE ) UNDER SIZE
Assembly
End User
No Effect
288 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
No Effect
PAGE NO- 121 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

Height Gauge
DEPTH DISTANCE Part get rejected at final inspection 4). Wrong Tool offset
UNDER SIZE
No Effect
End User

67 Ø10.00
Height Gauge
MILLING - 2 PLACES DEPTH DISTANCE control for parameter
7 3 4 84
( A2 -SIDE ) OVER SIZE 5). Key lock for un authorised access & Program
End User
No Effect
7 2 6 84
146. ( 15.00±0.50mm ). Assembly
End User
No Effect
6 3 5 90
part
SPOT FACE DIAMETER FOR FOR End User

"ACC" PUNCH No Effect
---
( REC 10.00±0.20 X 15.00±0.20mm )
& ( R5.00±0.50mm ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
100.(59) 3). Key lock for un authorised access & Program
Ø10.00MM END control for parameter
MILLING - 1 PLACE ( DIAMETER Part get rejected at final inspection
FOR "ACC" PUNCH 7 3 4 84
UNDER SIZE
PURPOSE ) Assembly
( A2 - SIDE )
End User
No Effect
SPOT FACE DEPTH DISTANCE ON Part get rejected at final inspection 4). Wrong Tool offset
--- Ø10.00 FOR "ACC" PUNCH 6 3 4 72
( 27.40±0.50mm ) Assembly 5). Wrong work offset
End User
No Effect
PAGE NO- 122 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

SPOT FACE DEPTH DISTANCE ON 4). Key lock for un authorised access & Program Caliper
--- Ø10.00 FOR "ACC" PUNCH 7 control for parameter 3 4 84
SIZE
( 29.40±0.50mm )
100.(59)
Ø10.00MM END End User
MILLING - 1 PLACE ( No Effect
FOR "ACC" PUNCH
PURPOSE ) Next Operation 1). Program change
( A2 - SIDE ) Master program verification at Job set up
CENTER DISTANCE ONØ10.00 FOR 3). Preventive maintainance Plan Preventive maintainance Record (ISCII-TS-MTC-
"ACC" PUNCH Subsequent Operation 3). Machine axis variation (machine wear)
---- 7 2 6 84
SPECIFICATION Part get rejected at final inspection
( 30.00±0.25mm ),
( 120.00±0.25mm ). Assembly
End User
No Effect
SIZE
Ø10.00MM END Fitment problem not mating with mating part
MILLING - 1 PLACE End User
DEPTH DISTANCE ON MACHINING
( FOR MACHINING
--- DATA BOX No Effect
DATA BOX
( 66.00±0.50mm )
PURPOSE ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
( DATUM 'E'
OPPOSITE SIDE )
DEPTH UNDER 4). Key lock for un authorised access & Program Caliper
End User
No Effect
OPERATION NO :- 110 - ( DATUM "E" SIDE ) SPOT FACING, PORT FORMING, DRILLING, TAPPING & CHAMFERING
1). Product placed in wrong position while 1). Proper training provided for clamping
Next Operation 100% Visual Inspection with Fixture set up
clamping Operation standard ( OP/08/DFS-08 ).
1). Lead to tool breakage in current operation
2). Proper training provided for clamping
2). Can not achive the product specification in 2). Clamping tight variation 100% proper tighted (15 to 25 Nm ) with allen Key
Operation standard ( OP/08/DFS-08 ).
110.(01) current operation
IMPROPER Subsequent Operation
CLAMP THE JOB IN --- PROPER CLAMPING 7 2 6 84
CLAMPING
FIXTURE Part get rejected at final inspection
Assembly
No Effect
End User
No Effect
110.(02) part
Ø8.50MM DRILLING - HOLE DIAMETER ON M10 X 1.50 End User
27, 35
3 PLACES ( 3 X Ø8.50±0.50mm ) No Effect
( DATUM "E" -SIDE )
7 3 4 84
UNDER SIZE Assembly
End User
No Effect
PAGE NO- 123 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

caliper
6 3 4 72
End User

28, 36 No Effect
( 3 X x 14.50mm MAX )
caliper
End User
No Effect
paste
HEIGHT OUT OF Part get rejected at final inspection 6 2 4 48
SPECIFICATION
Assembly

110.(02) End User
Ø8.50MM DRILLING -
3 PLACES CHAMFER DIAMETER ON Ø8.50 No Effect
29, 37
( DATUM "E" -SIDE ) ( 3 X wØ10.50mm MAX )
paste
MISSING
Assembly
End User
No Effect
paste
CHAMFER ANGLE ON Ø8.50 OUT OF
30, 38 Part get rejected at final inspection 6 2 4 48
Assembly
End User
No Effect
OUT OF
34, 42 7 2 6 84
SPECIFICATION
(3X j | Ø0.50 | A | B | C ) Assembly
End User
No Effect
PAGE NO- 124 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

110.(02) 47, ( 37.00±0.25mm ),
Ø8.50MM DRILLING - 54, ( 116.00±0.25mm ), OUT OF
7 2 6 84
3 PLACES 43, ( 36.00±0.25mm ), SPECIFICATION
Assembly
( DATUM "E" -SIDE ) 49, ( 29.90±0.25mm ),
43, ( 36.00±0.25mm ),
46. ( 118.00±0.25mm ).
End User
No Effect
6 2 6 72
part
End User
THREAD No Effect
31, 39
( 3 X M10 X 1.50 - 6H ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
THREAD UNDER
Assembly 7 2 6 84
SIZE
End User
No Effect
6 3 4 72
110. (03) Assembly 5). Wrong work offset
M10 X 1.50 TAPPING
- 3 PLACES No Effect
( DATUM "E" -SIDE )
End User

32, 40
( 3 X x 11.00mm MIN )
7 3 4 84
End User
No Effect
POSITION ON M10 X 1.50 Part get rejected at final inspection
OUT OF
34, 42 7 2 6 84
SPECIFICATION
(3X j | Ø0.50 | A | B | C ) Assembly
End User
No Effect
PAGE NO- 125 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

CENTER DISTANCE ON M10 X 1.50 Master program verification at Job set up
110. (03) 47, ( 37.00±0.25mm ), 3). Preventive maintainance Plan Preventive maintainance Record (ISCII-TS-MTC-
M10 X 1.50 TAPPING 54, ( 116.00±0.25mm ), OUT OF ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
7 2 6 84
- 3 PLACES 43, ( 36.00±0.25mm ), SPECIFICATION Part get rejected at final inspection
( DATUM "E" -SIDE ) 49, ( 29.90±0.25mm ), Assembly
43, ( 36.00±0.25mm ),
46. ( 118.00±0.25mm ).
End User
No Effect
part
33, 41 No Effect
( 3 X Ø8.670 to Ø8.705mm )
7 3 4 84
UNDER SIZE Assembly
End User
No Effect
control for parameter Nos once periodic inspection with Digital vernier
SIZE
End User
32, 40
( 3 X x 11.00mm MIN ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
110.(04) control for parameter Nos once periodic inspection with Digital vernier
Ø8.69MM REAMING - 4). Key lock for un authorised access & Program caliper
3 PLACES 7 control for parameter 3 4 84
SIZE
( DATUM "E" SIDE ) 5). Key lock for un authorised access & Program
End User
No Effect
34, 42 7 2 6 84
SPECIFICATION
(3X j | Ø0.50 | A | B | C ) Part get rejected at final inspection
Assembly
End User
No Effect
CENTER DISTANCE ON Ø8.67 2). Key lock for un authorised access & Program inspection with CMM
47, ( 37.00±0.25mm ), Subsequent Operation 3). Machine axis variation (machine wear)
54, ( 116.00±0.25mm ), 7 2 6 84
43, ( 36.00±0.25mm ),
43, ( 36.00±0.25mm ), Assembly
46. ( 118.00±0.25mm ). Fitment problem not mating with mating part
End User
No Effect
8 2 6 96
49. ( 29.90±0.25mm ).
Assembly
End User
No Effect
PAGE NO- 126 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

part
End User
234
UNDER SIZE
End User
No Effect
Caliper
6 3 4 72
End User
110. (05)
Ø4.00MM DRILLING - HOLE DEPTH ON Ø4.00 No Effect
235
1 PLACE ( x 17.00±0.50mm )
( DATUM "E" -SIDE ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
Caliper
SIZE
End User
No Effect
POSITION ON Ø4.00 ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
OUT OF
SPECIFICATION
( j | Ø0.50 | E | F-G | G )
Assembly

End User
No Effect
120. ( 106.00±0.25mm ). Assembly
End User
No Effect
PAGE NO- 127 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

part
End User
HOLE DIAMETER
240 No Effect
( Ø4.00±0.50mm )
7 3 4 84
UNDER SIZE Assembly
End User
No Effect
Caliper
6 3 4 72
End User

241
( x 42.00±0.50mm )
110. (06)
Ø4.00MM DRILLING -
1 PLACE
( DATUM "E" -SIDE ) 3). Key lock for un authorised access & Program
Caliper
7 3 4 84
End User
No Effect
OUT OF
242 7 2 6 84
SPECIFICATION
( j | Ø0.50 | E | F | G ) Assembly
End User
No Effect
OUT OF
7 2 6 84
123. ( 135.00±0.25mm ). Assembly
End User
No Effect
PAGE NO- 128 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

part
End User
HOLE DIAMETER
243 No Effect
( Ø4.00±0.50mm )
7 3 4 84
UNDER SIZE Assembly
End User
No Effect
Caliper
6 3 4 72
End User

244
( x 7.00±0.50mm )
110. (07)
Ø4.00MM DRILLING -
1 PLACE
( DATUM "E" -SIDE ) 3). Key lock for un authorised access & Program
Caliper
7 3 4 84
End User
No Effect
OUT OF
245 7 2 6 84
SPECIFICATION
( j | Ø0.50 | E | F | G ) Assembly
End User
No Effect
OUT OF
7 2 6 84
124. ( 133.50±0.25mm ). Assembly
End User
No Effect
PAGE NO- 129 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

Gauge
6 3 5 90
part
End User
No Effect
HOLE DIAMETER
246
( Ø20.00±0.50mm )
Nos once periodic inspection with CMM (or) Plug
DIAMETER
7 3 4 84
UNDER SIZE
Assembly
End User
No Effect
6 3 4 72
110. (08)
End User
Ø20.00MM DRILLING
- 1 PLACE HOLE DEPTH ON Ø20.00 No Effect
( DATUM "E" -SIDE ) 247
( x 13.00±0.50mm )
SIZE
End User
No Effect
POSITION ON Ø20.00
248 7 2 6 84
SPECIFICATION
( j | Ø0.50 | E | F-G | G ) Assembly
End User
No Effect
7 2 6 84
125. ( 95.00±0.25mm ). Assembly

End User
No Effect
PAGE NO- 130 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

Gauge
6 3 5 90
part
End User
No Effect
HOLE DIAMETER
249
( Ø18.00±0.50mm )
DIAMETER
7 3 4 84
UNDER SIZE
Assembly
End User
No Effect
6 3 4 72
110. (09)
End User
Ø18.00MM DRILLING
( x 21.00±0.50mm )
SIZE
End User
No Effect
POSITION ON Ø18.00
251 7 2 6 84
SPECIFICATION
( j | Ø0.50 | E | F-G | G ) Assembly
End User
No Effect
7 2 6 84
121. ( 6.50±0.25mm ). Assembly

End User
No Effect
PAGE NO- 131 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

Gauge
6 3 5 90
part
End User
No Effect
HOLE DIAMETER
237
( Ø12.00±0.50mm )
DIAMETER
7 3 4 84
UNDER SIZE
Assembly
End User
No Effect
6 3 4 72
110. (10)
End User
Ø12.00MM DRILLING
( x 15.00±0.50mm )
SIZE
End User
No Effect
POSITION ON Ø12.00
239 7 2 6 84
SPECIFICATION
( j | Ø0.50 | E | F-G | G ) Assembly
End User
No Effect
7 2 6 84
126. ( 84.50±0.50mm ). Assembly

End User
No Effect
PAGE NO- 132 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

6 3 5 90
part
End User
254 B 8
( Ø5.00(-0.00 to +0.10)mm )
DIAMETER
7 3 4 84
UNDER SIZE Assembly
End User
No Effect
254 C. 7 2 6 84
SPECIFICATION
End User
No Effect
Ø5.00MM DRILLING -
1 PLACE No Effect 2). Tool built up edge 2). Alarm & lock in machine for tool life excess
( DATUM "E" -SIDE )
6 3 4 72
SIZE

254 E.
End User
No Effect
tester
254 D. 6 2 5 60
SPECIFICATION
Assembly
( Rz 7 to 30 )
End User
Performance Low
PAGE NO- 133 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

6 3 5 90
part
254 F.
( Ø5.00±0.10mm )
No Effect
DIAMETER
7 3 4 84
Assembly
End User
No Effect
POSITION ON Ø5.00
OUT OF
256 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
No Effect
110. (11)
1 PLACE
( DATUM "E" -SIDE )
Caliper
6 3 4 72
End User

255
( x28.00±0.50mm ).
Caliper
7 3 4 84
End User
No Effect
132. ( 11.00±0.50mm ). Assembly
End User
No Effect
PAGE NO- 134 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

part
End User
SPOT FACE DIAMETER
252 No Effect
( vØ10.00±0.50mm )
7 3 4 84
UNDER SIZE
Assembly
End User
No Effect
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
No Effect
110. (12) No Effect 2). Tool built up edge 2). Alarm & lock in machine for tool life excess
Ø10.00MM END Master program verification at Job set up and 5
MILLING - 1 PLACE Subsequent Operation 3). Wrong Tool selection Nos once periodic inspection with CMM (or) 2D
( DATUM "E" -SIDE ) Height Gauge
SIZE
No Effect
End User
No Effect
253
( x0.50±0.20mm ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
Height Gauge
7 3 4 84
End User
No Effect
OUT OF
Assembly 7 2 6 84
132. ( 11.00±0.50mm ).
End User
No Effect
PAGE NO- 135 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

Groove Vernier Caliper
6 3 5 90
part
End User
No Effect
HOLE DIAMETER
183 Q
( Ø12.20±0.20mm )
Nos once periodic inspection with CMM (or)
Subsequent Operation 3). Wrong Tool selection Groove Vernier Caliper
DIAMETER
7 3 4 84
UNDER SIZE
Assembly
End User
No Effect
3). Key lock for un authorised access & Program Nos once periodic inspection with Digital Height
Gauge
End User
110. (13) No Effect
Ø12.20MM DRILLING HOLE DEPTH ON Ø12.20
- 1 PLACE 257 P
( 21.45±0.20mm REF ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
( DATUM "E" -SIDE )
7 3 4 84
End User
No Effect
Gauge
DEPTH DISTANCE Part get rejected at final inspection 4). Key lock for un authorised access & Program
UNDER SIZE control for parameter
End User
No Effect
HOLE DEPTH DISTANCE ON
183 R Ø12.20 Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
( 31.65±0.20mm )
OVER SIZE Assembly 5). Wrong work offset
End User
No Effect
PAGE NO- 136 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

OUT OF
258 7 2 6 84
SPECIFICATION
( j | Ø0.30 | E | F-G | G ) Assembly
End User
110. (13)
No Effect
Ø12.20MM DRILLING
- 1 PLACE 1). Key lock for un authorised access & Program
( DATUM "E" -SIDE ) control for parameter Master program verification at Job set up
OUT OF
7 2 6 84
Assembly
133. ( 11.00±0.50mm ).
End User
No Effect
6 3 5 90
part
End User
No Effect
SPOT FACE DIAMETER
257 G
( Ø21.30±0.10mm )
DIAMETER
7 3 4 84
UNDER SIZE
Assembly
110. (14) End User

ES. 1352 (M18 X
1.50) PORT FORM No Effect
TOOL Ø16.50 &
21.30 - 1 PLACE Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
( DATUM "E" -SIDE )
Caliper
End User
No Effect
257 L
( 9.00mm REF ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
7 3 4 84
End User
No Effect
PAGE NO- 137 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

DEPTH DISTANCE Part get rejected at final inspection 4). Key lock for un authorised access & Program
UNDER SIZE control for parameter
End User
HOLE DEPTH DISTANCE ON No Effect

257 O Ø21.30
( 28.95±0.20mm )
8 3 4 96
End User
No Effect
SPECIFICATION
( Ra 3.20 Assembly
Rz 25 )
End User
110. (14)
ES. 1352 (M18 X Performance Low
1.50) PORT FORM 1). Key lock for un authorised access & Program
TOOL Ø16.50 & Next Operation 1). Program change Master program verification at Job set up
21.30 - 1 PLACE inspection & Day once periodic inspection with
( DATUM "E" -SIDE ) No Effect 2). Wrong work offset CMM
OUT OF
257 H 7 2 6 84
SPECIFICATION
( r | Ø0.40 | Q ) Assembly
End User
No Effect
control for parameter inspection & Day once periodic inspection with
No Effect 2). Wrong work offset CMM
OUT OF
257 N 7 2 6 84
SPECIFICATION
Assembly
( b | 0.10 | Q )
End User
No Effect
OUT OF
257 D 7 2 6 84
SPECIFICATION
Assembly
( h | 0.10 | Q )
End User
No Effect
PAGE NO- 138 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

moulded paste
6 2 4 48
SPECIFICATION
Assembly
End User
No Effect
257 I
( Ø19.30±0.10mm ) Next Operation 1). Tool wear out (Life excess) 1). Alarm & lock in machine for tool life excess
moulded paste
MISSING
Assembly
End User
No Effect
PORT 'C' BORE SURFACE FINISH Subsequent Operation 3). Wrong offset
257 C 6 ( ISCII-TS-MTC-PMP/C-R04 ) 2 4 48
SPECIFICATION
( Ra 3.20 Assembly
Rz 16 )
End User
110. (14)
ES. 1352 (M18 X Performance Low
1.50) PORT FORM
TOOL Ø16.50 &
21.30 - 1 PLACE
( DATUM "E" -SIDE ) Master program verification at Job set up
moulded paste
257 B 6 2 4 48
Assembly
End User
No Effect
paste
6 2 4 48
SPECIFICATION
Assembly
End User

257 S
( 2.00±0.20mm ) Next Operation 1). Tool wear out (Life excess) 1). Alarm & lock in machine for tool life excess
paste
DEPTH MISSING 6 2 5 60
Assembly
End User
No Effect
PAGE NO- 139 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

paste
6 2 4 48
SPECIFICATION
Assembly
End User
PORT 'C' BORE OUTER NOSE
RADIUS ON Ø19.30 No Effect
257 E
( R0.20±0.10mm X 45° ) Next Operation 1). Tool wear out (Life excess) 1). Alarm & lock in machine for tool life excess
paste
Assembly
End User
No Effect
paste
6 2 4 48
SPECIFICATION
Assembly
110. (14) End User

ES. 1352 (M18 X PORT 'C' BORE INNER NOSE
1.50) PORT FORM RADIUS ON Ø19.30 No Effect
257 F
TOOL Ø16.50 &
21.30 - 1 PLACE ( R1.00mm MAX ) Next Operation 1). Tool wear out (Life excess) 1). Alarm & lock in machine for tool life excess
( DATUM "E" -SIDE ) Master program verification at Job set up
paste
Assembly
End User
No Effect
6 3 5 90
part
End User
No Effect
HOLE DIAMETER ON M18 X 1.50 -
257 K 6H Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
( Ø16.60±0.05mm )
control for parameter caliper

DIAMETER
7 3 4 84
UNDER SIZE Assembly
End User
No Effect
PAGE NO- 140 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

RAW MATERIAL FROM FOUNDRY TO MACHINE SHOP 1). Tool wear out (Life excess) 1). Alarm & lock in machine for tool life excess
PORT 'C' BORE ANGLE END ON
257 A Ø19.30 6 2 4 48
SPECIFICATION
( 45°±5° ) Assembly
End User
No Effect
End User
257 Q
( x 19.00±0.20mm)
110. (14) 3). Key lock for un authorised access & Program Master program verification at Job set up and 5
ES. 1352 (M18 X control for parameter
1.50) PORT FORM 4). Key lock for un authorised access & Program caliper
TOOL Ø16.50 & 7 control for parameter 3 4 84
SIZE
21.30 - 1 PLACE 5). Key lock for un authorised access & Program
( DATUM "E" -SIDE ) control for parameter
End User
No Effect
POSITION ON M18 X 1.50 - 6H 3). Preventive maintainance Plan Preventive maintainance Record (ISCII-TS-MTC-
PORT ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
OUT OF
SPECIFICATION
( j | Ø0.30 | E | F-G | G ) Assembly
End User
No Effect
CENTER DISTANCE ON M18 X 1.50 - Subsequent Operation 3). Machine axis variation (machine wear)
6H PORT
130, SPECIFICATION
( 15.40±0.15mm ), Assembly
133.
( 11.00±0.15mm ).
End User
No Effect
Loose Fitment problem not mating with mating part

110. (15)
End User
M18 X 1.50 - 6H THREAD
257 J No Effect
TAPPING - 1 PLACE ( M18 X 1.50 - 6H )
7 2 6 84
SIZE
Assembly
End User
No Effect
PAGE NO- 141 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

6 3 4 72
No Effect
End User
THREAD DEPTH ON M18 X 1.50 - No Effect

257 R 6H
7 3 4 84
110. (15) End User

M18 X 1.50 - 6H
( DATUM "E" -SIDE )
POSITION ON M18 X 1.50 - 6H
OUT OF
258 7 2 6 84
SPECIFICATION
Assembly
( j | Ø0.30 | E | F-G | G )
End User
No Effect
OUT OF
7 2 6 84
SPECIFICATION
130, ( 15.40±0.50mm ), Assembly
133. ( 11.00±0.50mm ).
End User
No Effect
Can not achive the dimension Ø10.00(-0.000 to
DIAMETER OVER
5 4). Preventive maintainance Plan 2 5 50
SIZE Part get rejected at final inspection 4). Tool worn out Preventive maintainance Record (ISCII-TS-MTC-
No Effect
110.(16)
BORE DIAMETER ON Ø10.00(-0.000
ES. CDS - 068 PORT End User
to +0.027) STOCK
FORM ROUGHING ---
No Effect
TOOL - 1 PLACE
( DATUM "E" -SIDE )
DIAMETER
UNDER SIZE
Assembly
No Effect
End User
No Effect
PAGE NO- 142 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

process
SIZE
End User
BORE DEPTH ON Ø9.50 No Effect

---
( x 2.00±0.10mm )

Subsequent Operation 3). Wrong Tool selection Master program verification
7 3 4 84
No Effect
End User
No Effect
Can not achive the dimension Ø9.60(-0.00 to
110.(16) 5). Preventive maintainance Plan PMP-R05) with CMK study
ES. CDS - 068 PORT Assembly 5). Machine axis variation (machine wear)
FORM ROUGHING
No Effect
TOOL - 1 PLACE
HOLE DIAMETER ON Ø9.60(-0.00 to
( DATUM "E" -SIDE ) End User
+0.10) STOCK
---
No Effect
( Ø9.00±0.10mm )
DIAMETER
UNDER SIZE
Assembly
No Effect
End User
No Effect
process
BORE DEPTH ON Ø9.00 End User

---
( x 3.50±0.05mm )
No Effect
No Effect
End User
No Effect
PAGE NO- 143 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

Can not achive the dimension Ø6.00±0.20 mm in
110.17th process and get rejected at 110.17th 2). Tool built up edge 2). Alarm & lock in machine for tool life excess Tool verification as per tool package sheet before
process part setting
No Effect
DIAMETER ON Ø6.00±0.20 STOCK End User
---
No Effect
( Ø5.50±0.20mm )
DIAMETER
UNDER SIZE
Assembly
No Effect
End User
No Effect
process
SIZE
End User
110.(16)
ES. CDS - 068 PORT BORE DEPTH ON Ø5.50 No Effect
---
FORM ROUGHING ( x 3.80±0.10mm )
TOOL - 1 PLACE Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
( DATUM "E" -SIDE )
7 3 4 84
No Effect
End User
No Effect
Master program verification
POSITION ON Ø9.50
--- 5 2 5 50
SPECIFICATION
( j | Ø0.50 | E | F-G | G ) Assembly
End User
No Effect
--- 5 2 4 40
( 38.70±0.50mm ). Assembly
End User
No Effect
PAGE NO- 144 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

No Effect 2). Tool built up edge 2). Alarm & lock in machine for tool life excess Nos once periodic inspection & 100% process
inspection with Air Plug Gauge (or) Plug Gauge &
3). Key lock for un authorised access & Program 4 Nos Per Day Xbar R Chart Inspected
8 2 5 80
part
End User
BORE DIAMETER No Effect
232 X
( Ø10.015±0.01mm )
Nos once periodic inspection & 100% process
3). Key lock for un authorised access & Program inspection with Air Plug Gauge (or) Plug Gauge &
control for parameter 4 Nos Per Day Xbar R Chart Inspected
8 3 4 96
UNDER SIZE Assembly
End User
No Effect
Subsequent Operation 3). Wrong Tool selection once periodic inspection with Profile Projector with
moulded paste
6 3 4 72
End User
110.(17)
ES. CDS - 068 PORT No Effect
FORM TOOL BORE DEPTH ON Ø10.00
232 R
REAMER ( 2.00±0.10mm )
( Ø10.00 & Ø9.60 ) - 1
PLACE
( DATUM "E" -SIDE )
moulded paste
7 3 4 84
End User
No Effect
paste
HEIGHT OUT OF Part get rejected at final inspection 6 2 4 48
SPECIFICATION
Assembly
End User
CHAMFER HEIGHT ON Ø10.00 No Effect

232 T
( 0.30±0.10mm )
paste
MISSING
Assembly
End User
No Effect
PAGE NO- 145 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

paste

CHAMFER ANGLE ON Ø10.00 OUT OF
232 U 6 2 4 48
Assembly
End User
No Effect
OUT OF
232 Y 8 2 6 96
SPECIFICATION
( j | Ø0.20m | A | B ) Assembly
End User
No Effect
OUT OF
7 2 6 84
Assembly
115. ( 37.00±0.10mm ).
110.(17)
ES. CDS - 068 PORT
FORM TOOL End User
REAMER
( Ø10.00 & Ø9.60 ) - 1 No Effect
PLACE
6 3 5 90
part
End User
232 W
( Ø9.60(-0.00 to +0.10)mm )
7 3 4 84
UNDER SIZE Assembly
End User
No Effect

Gauge (or) CMM
HOLE DEPTH ON Ø9.60 DEPTH OVER 4). Key lock for un authorised access & Program
232 Q Part get rejected at final inspection 8 4). Wrong Tool offset 2 5 80
( x 3.50±0.05mm ) SIZE control for parameter
End User
No Effect
PAGE NO- 146 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN


Gauge (or) CMM
232 Q 8 3 4 96
( x 3.50±0.05mm ) SIZE 5). Key lock for un authorised access & Program
End User
No Effect
paste

ANGLE ON Ø9.60 OUT OF
232 B 6 2 4 48
Assembly
End User
No Effect
paste
SPECIFICATION
110.(17) Assembly
ES. CDS - 068 PORT
FORM TOOL
REAMER End User
( Ø10.00 & Ø9.60 ) - 1
PLACE NOSE RADIUS ON Ø9.60 No Effect
( DATUM "E" -SIDE ) 232 A
( R0.30±0.20mm )
paste

Assembly
End User
No Effect
No Effect 2). Tool built up edge 2). Alarm & lock in machine for tool life excess inspection with Profile Projector with moulded
6 3 5 90
part
End User
DIAMETER No Effect
232 S
( Ø6.00±0.20mm )
No Effect 2). Tool wear out 2). Alarm & lock in machine for tool life excess Master program verification at Job set up
3). Key lock for un authorised access & Program inspection with Profile Projector with moulded
Subsequent Operation 3). Wrong Tool selection paste
7 3 4 84
UNDER SIZE Assembly
End User
No Effect
PAGE NO- 147 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

3). Key lock for un authorised access & Program once periodic inspection with Digital Vernier
control for parameter Caliper (or) Profile Projector with moulded paste &
4 Nos Per Day Xbar R Chart Inspected
6 3 4 72
End User
DEPTH ON Ø6.00 No Effect

232 V
( x3.80±0.10mm )
3). Key lock for un authorised access & Program once periodic inspection with Digital Vernier
control for parameter Caliper (or) Profile Projector with moulded paste &
4). Key lock for un authorised access & Program 4 Nos Per Day Xbar R Chart Inspected
7 3 4 84
End User
No Effect
paste
ES. CDS - 068 PORT
FORM TOOL ANGLE ON Ø6.00 OUT OF
232 C 6 2 4 48
REAMER ( 45°±2° ) SPECIFICATION
( Ø10.00 & Ø9.60 ) - 1 Assembly
PLACE
( DATUM "E" -SIDE ) Customer dissatisfaction at assembly
End User
No Effect

POSITION ON ES - 068 PORT (or)
OUT OF
233 7 2 6 84
SPECIFICATION
( j | Ø0.50 | E | F-G | G ) Assembly
End User
No Effect

CENTER DISTANCE ON ES - 068
PORT (or) Ø10.00 Part get rejected at final inspection
OUT OF
7 2 6 84
SPECIFICATION
116, ( 79.50±0.50mm ), Assembly
115. ( 37.00±0.50mm ).
End User
No Effect
PAGE NO- 148 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

6 3 5 90
part
End User
304
( Ø3.00±0.50mm )
7 3 4 84
UNDER SIZE Assembly
End User
No Effect
3). Key lock for un authorised access & Program Master program verification at Job set inspection
control for parameter with Profile Projector with moulded paste
6 3 4 72
End User
110.(18) No Effect
( 35.50±0.50mm )
( DATUM "E" -SIDE )
7 3 4 84
End User
No Effect
POSITION ON Ø3.00
OUT OF
305 7 2 6 84
SPECIFICATION
( j | Ø0.30 | E | F-G | G ) Assembly
End User
No Effect
232 Z, ( 1.50±0.15mm ), 7 2 6 84
SPECIFICATION
136, ( 78.00±0.15mm ), Assembly
116. ( 79.50±0.15mm ).
End User
No Effect
PAGE NO- 149 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

6 3 5 90
part
End User
306
( Ø3.00±0.50mm )
7 3 4 84
UNDER SIZE Assembly
End User
No Effect
6 3 4 72
End User
110.(19) No Effect
( 18.00±0.50mm )
( DATUM "E" -SIDE )
7 3 4 84
End User
No Effect
POSITION ON Ø3.00
OUT OF
307 7 2 6 84
SPECIFICATION
( j | Ø0.30 | E | F-G | G ) Assembly
End User
No Effect
116. ( 79.50±0.15mm ). Assembly
End User
No Effect
PAGE NO- 150 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

No Effect 2). Tool built up edge 2). Alarm & lock in machine for tool life excess Nos once periodic & 100% Process inspection
3). Key lock for un authorised access & Program with CMM (or) Plug Gauge
6 3 5 90
part
End User
232 L
( Ø4.40±0.05mm )
3). Key lock for un authorised access & Program Nos once periodic & 100% Process inspection
Subsequent Operation 3). Wrong Tool selection with CMM (or) Plug Gauge
7 3 4 84
UNDER SIZE Assembly
End User
No Effect
moulded paste
8 2 5 80
End User
110.(20) No Effect
ES. CDS - 068 PORT 232 P
( 5.15±0.10mm )
FORM TOOL Ø4.40 Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
& 3.20 - 1 PLACE
( DATUM "E" -SIDE ) No Effect 2). Tool wear out 2). Alarm & lock in machine for tool life excess
moulded paste
8 3 4 96
End User
No Effect
OUT OF
232 M 8 2 6 96
SPECIFICATION
( j | Ø0.05m | A | B ) Assembly
End User
No Effect
232 Z, OUT OF Part get rejected at final inspection
( 1.50±0.50mm ), 7 2 6 84
136, SPECIFICATION
( 78.00±0.50mm ), Assembly
116.
( 79.50±0.50mm ).
End User
No Effect
PAGE NO- 151 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

6 3 5 90
part
End User
232 J
( Ø3.20±0.10mm )
7 3 4 84
UNDER SIZE Assembly
End User
No Effect
moulded paste
8 2 5 80
End User
110.(20) No Effect
ES. CDS - 068 PORT HOLE DEPTH ON Ø3.20
232 N
FORM TOOL Ø4.40 ( 7.50±0.50mm )
& 3.20 - 1 PLACE
( DATUM "E" -SIDE )
moulded paste
8 3 4 96
End User
No Effect
OUT OF
232 K 7 2 6 84
SPECIFICATION
( r | Ø0.10m | C ) Assembly
End User
No Effect
paste
ANGLE ON Ø4.40 HOLE END AREA OUT OF
232 F Part get rejected at final inspection 6 2 4 48
Assembly
End User
No Effect
PAGE NO- 152 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

paste

OUT OF
6 2 4 48
SPECIFICATION
Assembly
End User
NOSE RADIUS ON Ø3.20 HOLE
232 E START AREA No Effect
( R0.20±0.20mm )
paste

Assembly
End User
No Effect
SURFACE FINISH ON Ø3.20 HOLE control for parameter
START AREA R0.20 4). Preventive maintainance Plan
232 D 6 ( ISCII-TS-MTC-PMP/C-R04 ) 2 4 48
SPECIFICATION
Assembly
( 1.60 Ry 10 )
110.(20)
ES. CDS - 068 PORT End User
FORM TOOL Ø4.40
Performance Low
& 3.20 - 1 PLACE
( DATUM "E" -SIDE )
paste
6 2 4 48
SPECIFICATION
Assembly
End User
DISTANCE ON Ø3.20 HOLE END
No Effect
232 H AREA
( 0.20±0.10mm )
paste

Assembly
End User
No Effect
paste
ANGLE ON Ø3.20 HOLE END AREA OUT OF
232 I Part get rejected at final inspection 6 2 4 48
Assembly
End User
No Effect
PAGE NO- 153 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

paste
110.(20) 3). Key lock for un authorised access & Program
ES. CDS - 068 PORT TIP ANGLE ON Ø3.20 HOLE END Subsequent Operation 3). Wrong offset
OUT OF control for parameter
FORM TOOL Ø4.40 232 G AREA 6 2 4 48
& 3.20 - 1 PLACE ( 150°±1° )
( DATUM "E" -SIDE ) Assembly
End User
No Effect
FIXTURE INDEX 90°

part
End User
HOLE DIAMETER ON M12 X 1.75
161 E No Effect
( Ø10.20±0.15mm )
Subsequent Operation 3). Wrong Tool selection Caliper
7 3 4 84
UNDER SIZE Assembly
End User
No Effect
110. (21)
Ø10.25MM DRILLING End User
( B1 -SIDE ) 161 G
( 30.75mm MAX )
SIZE
End User
No Effect
161 F 7 2 6 84
( j | Ø1.00 | E | F-G | G )
Assembly
End User
No Effect
7 2 6 84
60, ( 52.00±0.50mm ), SPECIFICATION Part get rejected at final inspection
70. ( 52.90±0.50mm ). Assembly
End User
No Effect
PAGE NO- 154 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

caliper (or) Plug Gauge
6 3 5 90
part
End User
No Effect
SPOT FACE DIAMETER
161 K
( Ø15.00±0.15mm )
DIAMETER
7 3 4 84
UNDER SIZE
Assembly
End User
No Effect
3). Key lock for un authorised access & Program Nos once periodic inspection with CMM (or) 2D
Height Gauge
6 3 4 72
SPOT FACE DEPTH DISTANCE ON
110. (22) End User
Ø15.00
Ø15.00MM SPOT 139 ( 126.90±1.00mm )
FACING - 1 PLACE No Effect
( B1 -SIDE ) &
161 J ( 1.50±0.15mm )
3). Key lock for un authorised access & Program Nos once periodic inspection with CMM (or) 2D
Height Gauge
7 3 4 84
End User
No Effect
OUT OF
162 7 2 6 84
SPECIFICATION
( j | Ø1.00 | E | F-G | G ) Assembly
End User
No Effect
70. ( 52.90±0.50mm ). Assembly
End User
No Effect
PAGE NO- 155 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

caliper (or) Plug Gauge
6 3 5 90
part
End User
No Effect
SPOT FACE DIAMETER
161 B
( Ø14.00±0.15mm )
DIAMETER
7 3 4 84
UNDER SIZE
Assembly
End User
No Effect
6 3 4 72
End User
110. (23)
Ø14.00MM SPOT
No Effect
FACING - 1 PLACE SPOT FACE DEPTH ON Ø14.00
161 I
( B1 -SIDE ) ( 4.00±0.15mm )
7 3 4 84
End User
No Effect
POSITION ON Ø14.00
162 7 2 6 84
SPECIFICATION
( j | Ø1.00 | E | F-G | G )
Assembly
End User
No Effect
7 2 6 84
70. ( 52.90±0.50mm ). Assembly
End User
No Effect
PAGE NO- 156 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

Loose Fitment problem not mating with mating part
End User
THREAD
161 C No Effect
( M12 X 1.75 )
7 2 6 84
SIZE
Assembly
End User
No Effect
6 3 4 72
No Effect
End User

161 H
110. (24) ( x 15.00mm MIN )
M12 X 1.75 TAPPING
- 1 PLACE
( B1 -SIDE ) No Effect 2). Tap wear out 2). Alarm & lock in machine for tool life excess
7 3 4 84
End User
No Effect
POSITION ON M12 X 1.75
OUT OF
162 7 2 6 84
SPECIFICATION
Assembly
( j | Ø1.00 | E | F | G )
End User
No Effect
CENTER DISTANCE ON M12 X 1.75
OUT OF
7 2 6 84
60, Assembly
( 52.90±0.50mm ).
70.
End User
No Effect
PAGE NO- 157 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

Gauge
6 3 5 90
part
End User
No Effect
HOLE DIAMETER
155
( Ø8.00±0.50mm )
DIAMETER
7 3 4 84
UNDER SIZE
Assembly
End User
No Effect
6 3 4 72
End User
110. (25)
Ø8.00MM DRILLING -
1 PLACE 156
( B1 -SIDE ) ( x79.00±0.25mm )
7 3 4 84
End User
No Effect
OUT OF
160 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
No Effect
72. ( 14.10±0.40mm ). Assembly
End User
No Effect
PAGE NO- 158 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

Gauge
6 3 5 90
part
End User
No Effect
HOLE DIAMETER
157
( Ø12.00±0.50mm )
DIAMETER
7 3 4 84
UNDER SIZE
Assembly
End User
No Effect
6 3 4 72
End User
110. (26)
Ø12.00MM DRILLING
- 1 PLACE 158
( B1 -SIDE ) ( x30.00±0.50mm )
7 3 4 84
End User
No Effect
OUT OF
160 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
No Effect
72. ( 14.10±0.40mm ). Assembly
End User
No Effect
PAGE NO- 159 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN
OPERATION NO :- 10 RAW MATERIAL FROM FOUNDRY TO MACHINE SHOP Master program verification at Job set up and 5
part
End User
SPOT FACE DIAMETER
159 L No Effect
( Ø25.00(-0.00 to +0.40)mm )
UNDER SIZE
Assembly
End User
No Effect
SURFACE FINISH ON Ø25.00 FACE 3). Key lock for un authorised access & Program
159 B 6 4). Preventive maintainance Plan 2 4 48
SPECIFICATION Part get rejected at final inspection 4). Machine axis variation (machine wear)
( 3.20 Rz 25 )
Assembly
End User
Performance Low
DEPTH OVER 4). Key lock for un authorised access & Program Caliper
110. (27) End User
502B0059 5.1 (6S 159 F No Effect
( 1.00mm MAX )
SAE) PORT FORM Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
TOOL No Effect 2). Tool wear out 2). Alarm & lock in machine for tool life excess
( Ø10.00 & Ø9.60 ) - 1 3). Key lock for un authorised access & Program Master program verification at Job set up and 5
PLACE Subsequent Operation 3). Wrong Tool selection
( B1 -SIDE ) 4). Key lock for un authorised access & Program Caliper
End User
No Effect
DISTANCE UNDER 4). Key lock for un authorised access & Program Gauge
End User
SPOT FACE DISTANCE ON Ø25.00
No Effect
139 FACE
DISTANCE OVER 4). Key lock for un authorised access & Program Gauge
End User
No Effect
CHAMFER HEIGHT ON Ø15.60 Subsequent Operation 3). Wrong offset
OUT OF
159 A Part get rejected at final inspection 6 2 4 48
SPECIFICATION
( -0.10 Assembly
-0.30 )
End User
No Effect
PAGE NO- 160 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

OUT OF
159 R 7 2 6 84
SPECIFICATION
Assembly
( b | 0.10 | A )
End User
No Effect
Caliper
6 3 4 72
End User

159 C
( 17.00(-0.00 to +1.00)mm )
Caliper
SIZE
110. (27)
502B0059 5.1 (6S
TOOL
( Ø10.00 & Ø9.60 ) - 1 No Effect
PLACE
( B1 -SIDE ) Next Operation 1). Tool wear out (Life excess) 1). Alarm & lock in machine for tool life excess
paste

OUT OF
6 2 4 48
SPECIFICATION
Assembly
End User
159 E
( 2.50(-0.00 to +0.40)mm ) No Effect
paste
Assembly
End User
No Effect
paste
TIP ANGLE ON Ø12.80 OUT OF
159 G Part get rejected at final inspection 6 2 4 48
Assembly
End User
No Effect
PAGE NO- 161 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

paste

OUT OF
6 2 4 48
SPECIFICATION
Assembly
End User

159 I No Effect
( R0.20±0.10mm )
paste

Assembly
End User
No Effect
110. (27) part
502B0059 5.1 (6S End User
TOOL No Effect
( Ø10.00 & Ø9.60 ) - 1 Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
( Ø12.80±0.10mm ).
PLACE
( B1 -SIDE ) No Effect 2). Tool wear out 2). Alarm & lock in machine for tool life excess Master program verification at Job set up and 5
UNDER SIZE
End User
No Effect
moulded paste
6 2 4 48
SPECIFICATION
Assembly
End User

159 K
( Ø15.60(-0.00 to +0.13)mm )
moulded paste
PORT 'C' BORE Part get rejected at final inspection 6 2 5 60
MISSING
Assembly
End User
No Effect
PAGE NO- 162 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

OUT OF
159 M 7 2 6 84
SPECIFICATION
Assembly
( h | 0.10 | A )
End User
No Effect
SPECIFICATION
Assembly
( 1.60 Rz 16 )
End User
Performance Low
paste

159 O 6 2 4 48
Assembly

502B0059 5.1 (6S
TOOL
( Ø10.00 & Ø9.60 ) - 1
No Effect
PLACE
OUT OF
159 P 7 2 6 84
SPECIFICATION
Assembly
( r | Ø0.30 | A )
End User
No Effect
paste
ANGLE ON Ø15.60 BOTTOM AREA OUT OF Subsequent Operation 3). Wrong offset
159 Q 6 control for parameter 2 4 48
Assembly
End User
No Effect
160 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
No Effect
PAGE NO- 163 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

110. (27) 3). Preventive maintainance Plan Preventive maintainance Record (ISCII-TS-MTC-
502B0059 5.1 (6S CENTER DISTANCE ON 6 SAE, 9/16- Subsequent Operation 3). Machine axis variation (machine wear)
SAE) PORT FORM 18 UN PORT
TOOL 7 2 6 84
SPECIFICATION
( Ø10.00 & Ø9.60 ) - 1 61, ( 49.00±0.50mm ), Assembly
PLACE 72. ( 14.10±0.50mm ).
( B1 -SIDE ) Fitment problem not mating with mating part
End User
No Effect
6 2 6 72
part
End User
No Effect
THREAD
159 J Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
( 9/16 - 18 UNF )
THREAD UNDER Assembly 7 2 6 84
SIZE
End User
No Effect
6 3 4 72
110. (28) SIZE 5). Key lock for un authorised access & Program
9/16 - 18 UNF control for parameter
TAPPING - 1 PLACE
No Effect
( B1 -SIDE )
End User

159 D
( x 12.70mm MIN )
7 3 4 84
End User
No Effect
OUT OF
160 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
No Effect
PAGE NO- 164 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

CENTER DISTANCE ON 9/16 - 18 3). Preventive maintainance Plan Preventive maintainance Record (ISCII-TS-MTC-
110. (28) Subsequent Operation 3). Machine axis variation (machine wear)
UNF ( ISCII-TS-MTC-PMP/C-R04 ) PMP-R05) with CMK study
9/16 - 18 UNF OUT OF
61, ( 49.00±0.40mm ),
( B1 -SIDE ) Assembly
72. ( 14.10±0.40mm ).
End User
No Effect
Gauge
part
End User
HOLE DIAMETER
171 No Effect
( Ø5.00±0.50mm )
UNDER SIZE
Assembly
End User
No Effect
End User
110. (29) HOLE DEPTH ON Ø8.00 No Effect
172
Ø5.00MM DRILLING - ( x92.00±0.50mm ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
1 PLACE
( B1 -SIDE ) No Effect 2). Tool wear out 2). Alarm & lock in machine for tool life excess
End User
No Effect
OUT OF
SPECIFICATION
( j | Ø0.80 | E | F-G | G )
Assembly
End User
No Effect
7 2 6 84
73. ( 5.90±0.40mm ). Assembly
End User
No Effect
PAGE NO- 165 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN
part
End User
SPOT FACE DIAMETER
173 L No Effect
( Ø25.00(-0.00 to +0.40)mm )
UNDER SIZE
Assembly
End User
No Effect
( 3.20 Rz 25 )
Assembly
End User
Performance Low
110. (30) End User
502B0059 5.1 (6S 173 F No Effect
( 1.00mm MAX )
End User
No Effect
End User
No Effect
139 FACE
End User
No Effect
OUT OF
173 A Part get rejected at final inspection 6 2 4 48
SPECIFICATION
( -0.10 Assembly
-0.30 )
End User
No Effect
PAGE NO- 166 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

OUT OF
173 R 7 2 6 84
SPECIFICATION
Assembly
( b | 0.10 | A )
End User
No Effect
Caliper
6 3 4 72
End User

173 C
( 17.00(-0.00 to +1.00)mm )
Caliper
SIZE
110. (30)
502B0059 5.1 (6S
TOOL
( Ø10.00 & Ø9.60 ) - 1 No Effect
PLACE
paste

OUT OF
6 2 4 48
SPECIFICATION
Assembly
End User
173 E
( 2.50(-0.00 to +0.40)mm ) No Effect
paste
Assembly
End User
No Effect
paste
Assembly
End User
No Effect
PAGE NO- 167 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

paste

OUT OF
6 2 4 48
SPECIFICATION
Assembly
End User

173 I No Effect
( R0.20±0.10mm )
paste

Assembly
End User
No Effect
110. (30) part
502B0059 5.1 (6S End User
TOOL No Effect
( Ø12.80±0.10mm ).
PLACE
UNDER SIZE
End User
No Effect
moulded paste
6 2 4 48
SPECIFICATION
Assembly
End User

173 K
( Ø15.60(-0.00 to +0.13)mm )
moulded paste
MISSING
Assembly
End User
No Effect
PAGE NO- 168 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

OUT OF
173 M 7 2 6 84
SPECIFICATION
Assembly
( h | 0.10 | A )
End User
No Effect
SPECIFICATION
Assembly
( 1.60 Rz 16 )
End User
Performance Low
paste

173 O 6 2 4 48
Assembly

502B0059 5.1 (6S
TOOL
( Ø10.00 & Ø9.60 ) - 1
No Effect
PLACE
OUT OF
173 P 7 2 6 84
SPECIFICATION
Assembly
( r | Ø0.30 | A )
End User
No Effect
paste
Assembly
End User
No Effect
174 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
No Effect
PAGE NO- 169 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

TOOL 7 2 6 84
SPECIFICATION
( Ø10.00 & Ø9.60 ) - 1 63, ( 15.00±0.50mm ), Assembly
PLACE 73. ( 5.90±0.50mm ).
End User
No Effect
6 2 6 72
part
End User
No Effect
THREAD
( 9/16 - 18 UNF )
SIZE
End User
No Effect
6 3 4 72
TAPPING - 1 PLACE
No Effect
( B1 -SIDE )
End User

173 D
( x 12.70mm MIN )
7 3 4 84
End User
No Effect
OUT OF
174 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
No Effect
PAGE NO- 170 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

63, ( 15.00±0.50mm ),
73. ( 5.90±0.50mm ).
End User
No Effect
6 3 5 90
part
End User
HOLE DIAMETER
163 No Effect
( Ø5.00±0.50mm )
7 3 4 84
UNDER SIZE
Assembly
End User
No Effect
End User
110. (32) HOLE DEPTH ON Ø5.00
Ø5.50MM DRILLING - 164 No Effect
( x75.50±0.50mm )
( B1 -SIDE )
SIZE
End User
No Effect
OUT OF
SPECIFICATION
( j | Ø0.80 | E | F-G | G )
Assembly
End User
No Effect
64. ( 14.00±0.50mm ). Assembly
End User
No Effect
PAGE NO- 171 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN
part
End User
SPOT FACE DIAMETER
165 L No Effect
( Ø25.00(-0.00 to +0.40)mm )
UNDER SIZE
Assembly
End User
No Effect
( 3.20 Rz 25 )
Assembly
End User
Performance Low
110. (33) End User
502B0059 5.1 (6S 165 F No Effect
( 1.00mm MAX )
End User
No Effect
End User
No Effect
118 FACE
End User
No Effect
165 A 6 2 4 48
SPECIFICATION
( -0.10 Assembly
-0.30 )
End User
No Effect
PAGE NO- 172 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

OUT OF
165 R 7 2 6 84
SPECIFICATION
Assembly
( b | 0.10 | A )
End User
No Effect
Caliper
6 3 4 72
End User

165 C
( 17.00(-0.00 to +1.00)mm )
Caliper
SIZE
110. (33)
502B0059 5.1 (6S
TOOL
( Ø10.00 & Ø9.60 ) - 1 No Effect
PLACE
paste

OUT OF
6 2 4 48
SPECIFICATION
Assembly
End User
165 E
( 2.50(-0.00 to +0.40)mm ) No Effect
paste
Assembly
End User
No Effect
paste
Assembly
End User
No Effect
PAGE NO- 173 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

paste

OUT OF
6 2 4 48
SPECIFICATION
Assembly
End User

165 I No Effect
( R0.20±0.10mm )
paste

Assembly
End User
No Effect
110. (33) part
502B0059 5.1 (6S End User
TOOL No Effect
( Ø12.80±0.10mm ).
PLACE
UNDER SIZE
End User
No Effect
moulded paste
6 2 4 48
SPECIFICATION
Assembly
End User

165 K
( Ø15.60(-0.00 to +0.13)mm )
moulded paste
MISSING
Assembly
End User
No Effect
PAGE NO- 174 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

OUT OF
165 M 7 2 6 84
SPECIFICATION
Assembly
( h | 0.10 | A )
End User
No Effect
SPECIFICATION
Assembly
( 1.60 Rz 16 )
End User
Performance Low
paste

165 O 6 2 4 48
Assembly

502B0059 5.1 (6S
TOOL
( Ø10.00 & Ø9.60 ) - 1
No Effect
PLACE
OUT OF
165 P 7 2 6 84
SPECIFICATION
Assembly
( r | Ø0.30 | A )
End User
No Effect
paste
Assembly
End User
No Effect
166 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
No Effect
PAGE NO- 175 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

TOOL 7 2 6 84
SPECIFICATION
( Ø10.00 & Ø9.60 ) - 1 68, ( 114.70±0.50mm ), Assembly
PLACE 64. ( 14.00±0.50mm ).
End User
No Effect
6 2 6 72
part
End User
No Effect
THREAD
( 9/16 - 18 UNF )
SIZE
End User
No Effect
6 3 4 72
TAPPING - 1 PLACE
No Effect
( B1 -SIDE )
End User

165 D
( x 12.70mm MIN )
7 3 4 84
End User
No Effect
OUT OF
166 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
No Effect
PAGE NO- 176 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

7 2 6 84
TAPPING - 1 PLACE SPECIFICATION Part get rejected at final inspection
67, (114.20±0.50mm ),
64. ( 14.00±0.50mm ).
End User
No Effect
6 3 5 90
part
168 B
( Ø5.00(-0.00 to +0.10)mm ) No Effect 8
DIAMETER
UNDER SIZE
Assembly
End User
No Effect
168 C. 7 2 6 84
SPECIFICATION

110. (35) End User
Ø5.00MM DRILLING -
1 PLACE No Effect
( B1 -SIDE )
DISTANCE UNDER 4). Key lock for un authorised access & Program
168 E.
End User
No Effect
3). Key lock for un authorised access & Program tester
( Rz 7 to 30 ) Assembly
End User
Performance Low
PAGE NO- 177 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

6 3 5 90
part
168 F.
( Ø5.00±0.10mm )
No Effect
DIAMETER
7 3 4 84
Assembly
End User
No Effect
POSITION ON Ø5.00
OUT OF
170 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
No Effect
110. (35)
1 PLACE
( B1 -SIDE )
Caliper
6 3 4 72
End User

169
( x50.00±0.40mm ).
Caliper
7 3 4 84
End User
No Effect
71. ( 37.00±0.40mm ). Assembly
End User
No Effect
PAGE NO- 178 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

part
End User
SPOT FACE DIAMETER
167 No Effect
( vØ10.00±0.50mm )
7 3 4 84
UNDER SIZE
Assembly
End User
No Effect
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
No Effect
( B1 -SIDE ) Height Gauge
UNDER SIZE
No Effect
End User
No Effect
139
(127.90±0.50mm ) Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
Height Gauge
7 3 4 84
End User
No Effect
OUT OF
Assembly 7 2 6 84
71. ( 37.00±0.40mm ).
End User
No Effect
PAGE NO- 179 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

caliper
6 3 5 90
part
End User
SPOT FACE DIAMETER FOR "LS" & No Effect

--- "TO" & "DL" PUNCH PURPOSE

DIAMETER
7 3 4 84
UNDER SIZE
Assembly
End User
No Effect
Caliper
Ø10.00MM END
MILLING - 3 PLACES Part get rejected at final inspection 4). Wrong Tool offset
( FOR "LS" & "DL" & 6 3 4 72
"TO" PUNCH Assembly 5). Wrong work offset
PURPOSE ) control for parameter
( B1 - SIDE )
End User
FOR "DL" & "LS" PUNCH
( 2 X 127.90±0.50mm ) No Effect
--- &
SPOT FACE DEPTH ON Ø10.00 Next Operation 1). Improper M/C Setup 1). Proper checked JSIR
FOR "TO" PUNCH
( 128.90±0.50mm )
Caliper
7 3 4 84
End User
No Effect

CENTER DISTANCE ONØ10.00 Subsequent Operation 3). Machine axis variation (machine wear)
( 60.00±0.50mm ), Part get rejected at final inspection
( 32.00±0.50mm ), OUT OF
---- 7 2 6 84
( 13.50±0.50mm ), Assembly
( 9.50±0.50mm ),
( 135.00±0.50mm ). Fitment problem not mating with mating part
End User
No Effect
PAGE NO- 180 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN
OPERATION NO :- 10
FIXTUE INDEX RAW MATERIAL FROM FOUNDRY TO MACHINE SHOP
270°
part
End User
No Effect
291 B
HOLE DIAMETER 8
( Ø5.00(-0.00 to +0.10)mm )

7 3 4 84
UNDER SIZE
Assembly
End User
No Effect
Next Operation 1). Program change Master program verification at Job set up and Day
291 C. 7 2 6 84
SPECIFICATION
Assembly
( e | 0.05 )
End User
110. (38)
1 PLACE
( B2 -SIDE )
6 3 4 72
End User

291 E.
( x7.00±0.50mm )
End User
No Effect
tester
291 D. 6 ( ISCII-TS-MTC-PMP/C-R04 ) 2 5 60
SPECIFICATION
Assembly
( Rz 7 to 30 )
End User
Performance Low
PAGE NO- 181 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

6 3 5 90
part
291 F.
( Ø5.00±0.10mm )
No Effect
DIAMETER
7 3 4 84
Assembly
End User
No Effect
POSITION ON Ø5.00
OUT OF
293 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
No Effect
110. (38)
1 PLACE
( B2 -SIDE )
Caliper
6 3 4 72
End User

292
( x81.00±0.50mm ).
Caliper
7 3 4 84
End User
No Effect
154. ( 13.00±0.50mm ). Assembly
End User
No Effect
PAGE NO- 182 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

part
End User
SPOT FACE DIAMETER
290 No Effect
( vØ10.00±0.50mm )
7 3 4 84
UNDER SIZE
Assembly
End User
No Effect
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
No Effect
UNDER SIZE
No Effect
End User
No Effect
109
Height Gauge
7 3 4 84
End User
No Effect
OUT OF
Assembly 7 2 6 84
154. ( 13.00±0.50mm ).
End User
No Effect
PAGE NO- 183 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

part
End User
No Effect
299 B
HOLE DIAMETER 8
( Ø4.00(-0.00 to +0.10)mm )

7 3 4 84
UNDER SIZE
Assembly
End User
No Effect
299 C. 7 2 6 84
SPECIFICATION
Assembly
( e | 0.05 )
End User
110. (40) No Effect

Ø4.00MM DRILLING -
( B2 -SIDE )
6 3 4 72
End User

299 E.
( x6.00±0.50mm )
End User
No Effect
tester
OUT OF
299 D. Assembly 6 2 5 60
SPECIFICATION
( Rz 7 to 30 )
End User
Performance Low
PAGE NO- 184 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

6 3 5 90
part
299 F.
( Ø4.00±0.10mm )
No Effect
DIAMETER
7 3 4 84
Assembly
End User
No Effect
POSITION ON Ø4.00
OUT OF
301 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
No Effect
110. (40)
1 PLACE
( B2 -SIDE )
Caliper
6 3 4 72
End User

300
( x30.00±0.50mm ).
Caliper
7 3 4 84
End User
No Effect
150. ( 13.40±0.40mm ). Assembly
End User
No Effect
PAGE NO- 185 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

part
End User
SPOT FACE DIAMETER
298 No Effect
( vØ10.00±0.50mm )
7 3 4 84
UNDER SIZE
Assembly
End User
No Effect
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
No Effect
UNDER SIZE
No Effect
End User
No Effect
109
Height Gauge
7 3 4 84
End User
No Effect
OUT OF
Assembly 7 2 6 84
150. ( 13.40±0.40mm ).
End User
No Effect
PAGE NO- 186 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

part
End User
No Effect
295 B
HOLE DIAMETER 8
( Ø4.00(-0.00 to +0.10)mm )

7 3 4 84
UNDER SIZE
Assembly
End User
No Effect
295 C. 7 2 6 84
SPECIFICATION
Assembly
( e | 0.05 )
End User
110. (42) No Effect

Ø4.00MM DRILLING -
( B2 -SIDE )
6 3 4 72
End User

295 E.
( x6.00±0.50mm )
End User
No Effect
tester
OUT OF
295 D. Assembly 6 2 5 60
SPECIFICATION
( Rz 7 to 30 )
End User
Performance Low
PAGE NO- 187 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

6 3 5 90
part
295 F.
( Ø4.00±0.10mm )
No Effect
DIAMETER
7 3 4 84
Assembly
End User
No Effect
POSITION ON Ø4.00
OUT OF
297 7 2 6 84
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
No Effect
110. (42)
1 PLACE
( B2 -SIDE )
Caliper
6 3 4 72
End User

296
( x82.00±0.50mm ).
Caliper
7 3 4 84
End User
No Effect
150. ( 13.40±0.40mm ). Assembly
End User
No Effect
PAGE NO- 188 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN

part
End User
SPOT FACE DIAMETER
294 No Effect
( vØ10.00±0.50mm )
7 3 4 84
UNDER SIZE
Assembly
End User
No Effect
SPECIFICATION
( j | Ø0.80 | E | F-G | G ) Assembly
End User
No Effect
UNDER SIZE
No Effect
End User
No Effect
109
Height Gauge
7 3 4 84
End User
No Effect
OUT OF
Assembly 7 2 6 84
150. ( 13.40±0.50mm ).
End User
No Effect
PAGE NO- 189 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN
OPERATION
OPERATION NO
NO :- 10 :-RAW
120 MATERIAL
DEBURRING
FROM FOUNDRY TO MACHINE SHOP
1). Excessive use or non standardised deburring 1). Effective training given to operator as per Work
Next Operation In-station 100% visual inspection by operators
tools instruction ( ISC-II-MS-WI-DFS-08A)
No Effect
BURR
120 FREE FROM BURRS AND DENT PROJECTIONS, Part get reject / rework at final inspection
--- 5 2 8 80
DEBURRING MARKS DENT MARKS &
DAMAGE. Assembly
End User
Reduced performance
OPERATION NO :- 130 PART ENGRAVING

1). Effective training given to operator as per Work
Next Operation 1). Operator carelessness In-station 100% visual inspection by operators
instruction (ISC-II-TS-MS-ENGR- WI - 35)
No Effect
1)Slippage in
Part get reject / rework at final inspection
without engraving 5 2 7 70
parts, Assembly
End User
130 ENGRAVING LETTERS VISIBILITY, No Effect

---
PART ENGRAVING LETTERS DISTANCE. 1). Effective training given to operator as per Work
Next Operation 1). Operator carelessness In-station 100% visual inspection by operators
instruction (ISC-II-TS-MS-ENGR- WI - 35)
No Effect
1) Engraving letters Part get reject / rework at final inspection

5 2 7 70
visibility low
Assembly
End User
No Effect
OPERATION NO :- 140 ENDOSCOPIC INSPECTION ( LIGHTING SOURCE WITH CAMERA )

1). Effective training given to inspector as per Work
Next Operation 1). Inspection Error
instruction ( ISC-TS-MR- LRO-D15 ) In-station 100% visual inspection with endoscopic
machine
2). Better lighting system to be provided to make
No Effect 2). Inspection Error
easy visualisation of oil ports
SAND OR
140
METALLIC PARTS
ENDOSCOPIC
CONTAMINATION Part get reject at final inspection
INSPECTION --- FREE FROM DEFECTS 5 2 8 80
AND LOOSE
( LIGHTING SOURCE
PARTICLES IN Assembly
WITH CAMERA )
CORED HOLE
End User
Reduced performance
OPERATION NO :- 150 FINAL INSPECTION

1). Effective training given to inspector as per Final In-station visual & Gauge inspection as per
Next Operation 1). Use of wrong gauges &inspection method
Quality Plan ( Customer format ) sampling plan AQL
No Effect
No Effect
150 IMPROPER
--- PROPER INSPECTION 7 2 7 98
FINAL INSPECTION INSPECTION
Assembly
Customer dissatisfaction at assembly &

Part get reject at assembly
End User
Reduced performance & Customer dissatisfaction
PAGE NO- 190 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN
OPERATION
OPERATION NO
NO :- 10 :-RAW
160 MATERIAL
ULTRASONIC CLEANING
FROM FOUNDRY TO MACHINE SHOP
1). Effective training given to operator as per Work
Next Operation 1). Improper cleaning method In-station 100% visual inspection by operators
instruction ( ISC-II-WI-SRDAN-01 )
No Effect
160
IDENTIFICATION Part get reject / rework at final inspection
ULTRASONIC --- FREE FROM IMPURITIES 5 2 8 80
OF IMPURITIES
CLEANING Assembly
End User
Reduced performance
OPERATION NO :- 170 MILLIPORE TESTING

1). Use of non standard oil & oiling witout 1). Effective training given to inspector as per Work In-station 1 / batch visual inspection with Millipore
Next Operation
glooves. instruction ( ISC-II-MS-WI-DFS-08A) Testing Machine
No Effect
APPEARANCE OF Subsequent Operation
RUST &
170
FREE FROM RUST & DUST PARTICLES SIZE - Part get reject / rework at final inspection
MILLIPORE --- 5 3 6 90
PARTICLES 0.8 mm MAX &
TESTING Assembly
MASS - 70 mg/m2
to 111 mg/m2 Customer dissatisfaction at assembly
End User
Life of the component reduce
OPERATION NO :- 180 RUST PREVENTIVE OILING

1). Use of non standard oil & oiling witout 1). Effective training given to operator as per In-station 100 % visual inspection by oil dipping
Next Operation
glooves. Packaging data sheet ( ISC-TS-QCD-PS-D04.52 ) person
No Effect
180 Part get reject / rework
RUST
RUST PREVENTIVE --- FREE FROM RUST 5 2 8 80
APPEARANCE
OILING Assembly
Customer dissatisfaction at assembly &
Part get reject at assembly
End User
Life of the component reduce
OPERATION NO :- 190 PACKING

1). Effective training given to operator as per
Next Operation 1). Use of non standard packing boxes In-station 100% visual inspection by operators
Packaging data sheet ( ISC-TS-QCD-PS-D04.52 )

No Effect 2). Poor material handling.
Part get reject

--- FREE FROM DAMAGE PARTS DAMAGED 5 2 8 80
Assembly
End User
Reduced performance
190
PACKING
Next Operation 1). Operator carelessness Every dispatch to check visual
No Effect
DEVIATION FROM No Effect

LABLE INFORMATION AS PER THE
--- CUSTOMER 4 1 8 32
CUSTOMER REQUIRMENT
REQUIREMENT
Assembly
Customer dissatisfaction at assembly & Parts

returned
End User
No Effect
PAGE NO- 191 OF192

COIMBATORE,
Detection
severity
Responsibility &
class
Occurrence
RPN
OPERATION
OPERATION NO
NO :- 10 :-RAW
200 MATERIAL
DESPATCH FROM FOUNDRY TO MACHINE SHOP
Next Operation 1). Improper handling 100% visual inspection
No Effect
200 No Effect
--- FREE FROM DAMAGE PARTS DAMAGED 4 2 8 64
DESPATCH
Assembly
Customer dissatisfaction at assembly & Parts

returned
End User
No Effect
Reason for revision : -

0 ---> New release,
1 ---> Reviewed and updated Customer Drawing revision changed ( Rev No---> "B" from Rev No---> "P5" ),
2 ---> Reviewed and updated Customer Drawing revision changed ( Rev No---> "C" from Rev No---> "B" ),
3 ---> Reviewed and updated Customer Drawing revision changed ( Rev No---> "D" from Rev No---> "C" ),
4 ---> Reviewed and updated remove internal 'K' parameters.
PREPARED BY: GANESAN.O APPROVED BY : S.SELVAM ISSUED BY : S.SELVAM
DATE : 15.05.2019 DATE : 15.05.2019 DATE : 15.05.2019
PAGE NO- 192 OF192

06) - Fmea For 11190722 - D

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06) - Fmea For 11190722 - D

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INDO SHELL CAST PVT LTD Refrence no : ISC-TS-CFT-FMEA-D11

UNIT-II, FAILURE MODE EFFECTIVE ANALYSIS Report no : CP/07/SRD-01

Current Process Action Results

OPERATION NO :- 10 RAW MATERIAL FROM FOUNDRY TO MACHINE SHOP

OPERATION NO :- 20 RAW MATERIAL INSPECTION

Causes poor machining

20. PARAMETERS Causes poor

OPERATION NO :- 30 RAW MATERIAL STORAGE

30. Problem in next operation

PAGE NO- 1 OF192

Current Process Action Results

OPERATION NO :- 10 Next Operation

OPERATION NO :- 40 RAW MATERIAL TRANSPORTATION FROM STORAGE AREA TO MACHINE SHOP

OPERATION NO :- 50 PRE MACHINING - 1 ( DATUM "E" OPPOSITE SIDE )

PAGE NO- 2 OF192

Current Process Action Results

60. 4). Preventive maintainance Plan Preventive maintainance Record (ISCII-TS-MTC-

TOTAL THICKNESS FOR No Effect

OPERATION NO :- 70 RAW MATERIAL INSPECTION

OPERATION NO :- 80 SURFACE GRINDING-1 ( DATUM "E" OPPOSITE SIDE )

SURFACE FINISH ON DATUM 'E' 3). Preventive maintainance Plan

80. End User

SURFACE FINISH ON DATUM 'E' 3). Preventive maintainance Plan

PAGE NO- 3 OF192

Current Process Action Results

OPERATION NO :- 10 RAW MATERIAL FROM FOUNDRY TO MACHINE SHOP

3). Preventive maintainance Plan

3). Preventive maintainance Plan

THICKNESS 4). Preventive maintainance Plan

OPERATION NO :- 90 SURFACE GRINDING-2 ( DATUM "E" -SIDE )

PAGE NO- 4 OF192

Current Process Action Results

DISTANCE UNDER 4). Preventive maintainance Plan

3). Preventive maintainance Plan

3). Preventive maintainance Plan

PAGE NO- 5 OF192

Current Process Action Results

100.(01) Subsequent Operation

HOLE DEPTH ON Ø10.70 No Effect

Load for the 100.4th process will be high and it

PAGE NO- 6 OF192

Current Process Action Results

1). Key lock for un authorised access & Program

PAGE NO- 7 OF192

Current Process Action Results

Master program verification at Job set up and 5

Tight Fitment problem not mating with mating part

Fitment problem not mating with mating part

Fitment problem not mating with mating part

Customer dissatisfaction at assembly

PAGE NO- 8 OF192

Current Process Action Results

1). Key lock for un authorised access & Program

Fitment problem not mating with mating part

100.(04) End User

Fitment problem not mating with mating part

Tight Fitment problem not mating with mating part

Fitment problem not mating with mating part

Fitment problem not mating with mating part

PAGE NO- 9 OF192

Current Process Action Results

OPERATION NO :- 10 RAW MATERIAL FROM FOUNDRY TO MACHINE SHOP

SPOT FACE DEPTH DISTANCE ON No Effect