Format No: F-ED-06 Rev No : 00 Eff. Dt. : 01.09.

2014
Doc.No.: FMEA/TL-01 A

POTENTIAL FAILURE MODE AND EFFECT ANALYSIS REV. NO. : 06

ORG. Date : 18.03.2021

DRG. REV. STATUS : As per ML of Customer

Product Familt / Part Name : Stop & Tail Lamp (12V R10/5W) Part No : 9951210054S0NRACD00T
Drawing

Model Year (s) / Vehicles (s) : Customer : Hero Motor Corp. Ltd Process Responsibility : Mr. Vivek Rajpoot, Mr. Sanjiv Sharma, Mr Shivam Singh,Mr Mukesh Yadav

Customer Approval (If Reqd.)

Core Team : Mr Vidyut Sinha, Mr Sanjiv Sharma, Mr Shivam Singh,Mr Mukesh Yadav

Current Process Responsibilit Action Results

Classification
y

Detection
Occurrence

Occurrence
Severity
Actions

Detection
Process Potential Effect(s) of

Severity
RPN
Function Requirements Potential Failure Mode Potential Cause(s) of Failure Controls Recommended Actions Taken

RPN
Step Failure Controls Detection & Target
Prevention Completion Completion
Date Date
Internal Process
Packing not as per packing std Material damage 7 Supplier ignorance 3 Packing Standard & W.I 3 63
Audit
Receiving & verification of raw
material is done as per material
Receiving of Raw Material Material not as per bill or invoice Stock plan disturb 6 Supplier ignorance Inform to Supplier 3 4 72
1a packing std. & Placed order, verify
(Glass Tube)
qty as per bill / Invoice, without any
physical damage of material/ box
Material is in damage condition Material reject 6 Supplier ignorance Inform to Supplier 3 4 72

Packing not as per packing std & Silica gel not Material damage & Internal Process
7 Supplier ignorance 3 Packing Standard & W.I 3 63
Receiving & verification of raw provided. Cointamination of Moisture Audit
material is done as per material
1b Receiving of BOPs packing std. & Placed order, verify Material not as per bill or invoice Stock plan disturb 6 Supplier ignorance Inform to Supplier 3 4 72
qty as per bill / Invoice, without any
physical damage of material/ box
Material is in damage condition Material reject 6 Supplier ignorance Inform to Supplier 3 4 72

Material receive for inspection w/o GIN Material lot controlling not done 7 Store In-Charge ignorance Inform to Supplier 3 3 63
Material with G.I.N. sent to RQA for
incoming inspection where inspection
& testing done as per Sampling Plan &
Inspection of Raw material
2 report filled in Incoming Inspection Dimensions Out of specification Effect in process 7 Supplier ignorance Inform to Supplier 3 Inspection standard 3 63
or BOP
Standard/Report as per B.O.P.
Inspection Standard. Entry made in
G.I.N. Entry Register. Material Condition not matched as per standard (As per
Effect in process 8 Supplier ignorance Inform to Supplier 3 Material Standard 3 72
MTC)

Matl. Unloaded to designated area,

identified & kept as per
Storage of receipt material
3 Storage/Location Plan for Material Wrong location Mix up problem 7 Location not identified 3 Storage Location Plan 3 63
in Store
received. Ok Material after inspection
move to store.

Internal Process
Material issue w/o issue slip Material stock planning disturb 6 3 3 54
Audit
On receiving Material Issue Slip, mat.
Material move to Old material stock expires in Internal Process
4 is issued maintaining FIFO & checking New material isue inplace of old one 7 FIFO not maintain 3 Colour define for FIFO 3 63
Manufacturing. some cases Audit
of Min/Max. Stock Level.
All material stock consume by production Production stop 6 3 Stock bin card 3 54

Tube Dia less than (8.50 ~ 9.00 mm) Material reject 6 Supplier ignorance Inform to Supplier 2 4 48
Incoming Inspection as
per sampling plan
Tube Dia more than (8.50 ~ 9.00 mm) Material reject 6 Supplier ignorance Inform to Supplier 2 4 48

LCL Decreases,Punch Thickness

Flare Length less than (21.5 + 0.5 mm) 6 2 6 72
decreases Daily Preventive
Setup Approval + In
Tube stopper ruber wear out Maintenance Check
Process
LCL increases,Punch thickness Sheet
Flare Length more than (21.5 + 0.5 mm) 2 2 6 72
increases

Flare Dia less than (11.5 ± 0.30 mm) Improper sealing 6 High melting 3 5 90
Setup approval+In
10 Flare Making Process
Flare Dia More than (11.5 ± 0.30 mm) Sealing Diameter more 6 Less melting 3 5 90

Setup approval+In
Flare Crack Bulb Milky 6 Due to Less melting 6 4 144
Process & 100%
Setup approval+In
Tube Crack Bulb Milky 6 H2 Pressure more Pressure Gauge 4 4 96
Process & 100%
Preventive Setup approval+In
Scratch Bulb Milky 6 Flare Pin wear out 3 4 72
Maintenance Process & 100%
Setup approval+In
Wrinkle Bulb Leakage 6 Less melting 2 4 48
Process & 100%

6 Preventive 3 Setup approval+In

Uneven deformation Improper sealing Flare Pin wear out 4 72
Maintenance Process & 100%
Setup approval+In
Crack Material reject 8 3 4 96
Process & 100%
Setup approval+In
Tube crack, Uneven flaring/lining , Uneven flaring pass Part rejection on next operation 8 3 4 96
100% Visual Inspection Process & 100%
11 less or more length of tubes shall not
of flared tube
pass to Stem operation Setup approval+In
Less length Flare pass LCL less on Sealex M/c 7 3 3 63
Process & 100%
Setup approval+In
More length Flare pass Stem crack 8 3 3 96
Process & 100%
diffecult to move & chances of
Big size bins use for movement 6 3 3 54
fall on floor & tube crack
Moving of flared tube to Tubes are move in small size bins &
12
Stem M/c not be over loaded
Bin overloaded tube crack 8 Not aware about Bin Loading 3 4 96

Cutting of small Ext. tubes Tube length is more Sealing Tip length more 7 3 Setup approval 3 63
Preventive
20 from a big length tube on Tube length as per specificaton Stopper bolt loose
machine Maintenance
Tube length is less Sealing crack 7 3 Setup approval 4 84

diffecult to move & chances of

Big size bins use for movement 6 3 3 54
fall on floor & tube crack
Moving of small Ext. tube Tubes are move in small size bins &
21
to Stem M/c not be over loaded
Bin overloaded tube crack 8 Not aware about Bin Loading 3 4 96

Prepared By: Reviewed By:

Approved By:
Format No: F-ED-06 Rev No : 00 Eff. Dt. : 01.09.2014
Current Process Responsibilit Action Results

Classification
y

Detection
Occurrence

Occurrence
Severity
Actions

Detection
Process Potential Effect(s) of

Severity
RPN
Function Requirements Potential Failure Mode Potential Cause(s) of Failure Controls Recommended Actions Taken

RPN
Step Failure Controls Detection & Target
Prevention Completion Completion
Date Date

Oven Temp Less Than (220 ± 10 °C) Zone - 3 Punch Crack Problem 6 Heat not proper Temp. meter 3 3 54
Setup approval
Oven Temp more Than (220 ± 10 °C) Zone-3 Stem deformation 6 Over heating Temp. meter 3 3 54

Oven Temp Less Than (230 ± 10 °C) Zone-2 Punch Crack Problem 6 Heat not proper Temp. meter 3 3 54
Setup approval
Oven Temp more Than (230 ± 10 °C) Zone - 2 Stem deformation 6 Over heating Temp. meter 3 3 54

Oven Temp less Than (240 ± 10 °C)Zone-1 Punch Crack Problem 6 Heat not proper Temp. meter 3 Setup approval 3 54

Oven Temp More Than (240 ± 10 °C)Zone-1 Stem deformation 6 Over heating Temp. meter 3 3 54
Weld Pocket clean
E1. Hook Bending Problem, 7 C1.Dust in Weld Pocket holes, & check 3 4 84
Flare to Lead In Wire Dist SL/SR less than (30.75 ± 0.5 Setup approvel+In
mm) E2. Hook Length Short (Filament Weld Pocket clean Process
7 C1.Dust in Weld Pocket holes, & check 3 4 84
load, Punch)
Weld Pocket clean 01
E1. Hook Slip Problem, 7 C1. Weld Pocket loose. & check 3 4 84
Flare to Lead In Wire Dist SL/SR More than (30.75 ± 0.5 Setup approvel+In
mm) Weld Pocket clean Process
E2. Hook length increase. 7 C2.Weld Pocket Wires are bend & check 3 84
To make a stem maintaining its flare
to lead wire distance,flare to punch Weld Pocket clean 01
distance, lead in wire inside glass E1.Hook Bending Problem, 7 C1.Dust in Weld Pocket holes, & check 3 4 84
length,run out,exhaust tube Flare to Lead In Wire Dist TL/TR Less than (33.75 ± 0.5 Setup approvel+In
strength,punch thickness, oven mm) E2. Hook Length Short (Filament Weld Pocket clean Process
30 Stem Making temperature for zone1, 2, & 3 as 7 C1.Dust in Weld Pocket holes, & check 3 4 84
load, Punch)
specified and maintaining its stem
shape,hole for gas filling, dumet wire 01
colour inside glass without any lead in Weld Pocket clean
Hook Slip Problem 7 C1. Weld Pocket loose. 3 4 84
wire missing, punch crack,without Flare to Lead In Wire Dist TL/TR More than (33.75 ± & check Setup approvel+In
exhaust tube, 0.5 mm) Process
Weld Pocket clean
E2. Hook length increase. 7 C2.Weld Pocket Wires are bend & check 3 4 84

Hook length high at next 01

Stem Length (SL/SR) more than (93 ± 1 mm) 6 C-1- Weld pocket depth more 3 4 72
operation
Setup Approval + In
Mounting height less for next C-1- Dust particle in weld pocket Air Cleaning by Process
Stem Length (SL/SR) less (93 ± 1 mm) 6 3 4 72
operation holes automatic

Temp. meter by 01
Less melting
sensor Setup approvel+In
Hole for gas filling (Through hole) Part Reject at next operation 6 3 3 54
process
Less air Flow meter

Punch Thickness more (4.5 ± 0.5 mm) Improper getter application 6 3 3 54

Preventive
Flare Pusher wear out Setup approvel
Maintenance
Punch Thickness less (4.5 ± 0.5 mm) Improper getter application 6 3 3 54

Dumet Wire colour inside glass Golden Colour (Limit

Milky Bulb or Black Bulb 7 Improper melting Temp. meter 3 Setup approvel 3 63
Samples) not match

Crack 7 3 3 63
100% visual insprction done for :
31 100% visual inspection. Material Rejected Operator not inspection
Crack, Ex. Tube Broken
Ex. Tube Broken 7 3 3 63

Stem moved to Mount OK Stem are move in bins & not be

32 Material over loaded Material reject 6 3 3 54
Machine over loaded

01
Flare to filament distance less than ( 28.35 ± 0.5 mm) E1.L.C.L Decrease, 6 C1.Hook bending increase. 3 3 54
Setup approvel+In
process
Flare to filament distance more than ( 28.35 ± 0.5 mm) E1.L.C.L Increase. 6 C1. Hook bending decrease. 3 3 54

C1.Mounting distance assembly not

Mounting distance 21W less than (8.5 ± 0.5 mm) E1.Filament cut 7 working properly. 3 01 4 84

Setup approvel+In
E1.Lumen High, 7 3 procees 4 84
C1.Mounting distance assembly not
Mounting distance 21W more than (8.5 ± 0.5 mm)
working properly.
E2.Shell loading problem, 7 3 4 84

E1.5W filament burn due to high

Distance between X-Axis less then ( 2.8 ± 1 mm) 7 4 5 140
temperature of 21W. Preventive
C1.Pressing plate wear out Setup approvel
Maintenance
Distance between X-Axis more then ( 2.8 ± 1 mm) E2.No effect. 7 4 5 140

E1.5W filament burn due to high

Distance between Y-Axis less then ( 2.8 ± 1 mm) temperature of 21W. 7 4 5 140
Preventive
C1.Pressing plate wear out
Maintenance
Distance between Y-Axis more then ( 2.8 ± 1 mm) E1. No effect 7 4 5 140

To make a mount maintaining its flare Filament not secured properly
to filament distance,mounting
distance,hook thikness,hook
length,distance b/w filament x-
40 Mount Making Axis,Y-Axis,Flat thickness,wire flat
length, hook properly closed,filament Current (Stop Filament) less then 0.67 ~ 0.81 Amp
coil length, current ,lumen and
filament secured properly without any Current (Stop Filament) more then 0.67 ~ 0.81 Amp
filament missing, one hook bend,
Setup approvel+In
filament cramping not properly, 6 Pressing plate wear out 3
process
3 54
Filament coil length
lumen less 6 Improper Stretch Assembly 3 Setup approvel 3 54
(Stop Filament) more then 7mm max
Light intensity low 7 2 01 3 42
Setup approvel+In
process
Light intensity high 7 2 3 42
Current (Top Filament) less then 0.41 ~ 0.49 Amp Light intensity low 7 Shape die wear out 2 01 4 56
preventive Setup approvel+In
maintenance process
Current (Top Filament) more then 0.41 ~ 0.49 Amp Light intensity high 7 Shape die thickness high 2 4 56
Mounting distance high
Lumen (Stop Filament) less then 100 ~ 150 lm Light intensity low 7 2 01 4 56
Setup approvel+In
Mounting distance less process
Lumen (Stop Filament) more then 100 ~ 150 lm Light intensity high 7 2 4 56
Mounting distance high
Lumen (Tail Filament) less then 21~31 lm Light intensity low 7 2 Setup approvel+In 4 56
Mounting distance less process
Lumen (Tail Filament) more then 21~31 lm Light intensity high 7 2 4 56
impurities will stuck with filament
Visual Inspection/Glow Automatic filament loader installed in mount Tool Room
Filament cut Bulb will not glow 7 3 4 84 machine. 12.12.2017 7 2 4 56
Testing at PDI 03
12.12.2017

Visual Inspection/Glow Automatic filament loader vibrator covered Tool Room

Filament cut Bulb will not glow 7 3 4 with glass frame. 15.12.2018
15.12.2018 7 2 5 70
Testing at PDI 04

To prevent suction of impurities with filament,

Visual Inspection/Glow Tool room
Filament cut Bulb will not glow 7 due to presence of contamination 3 4 84 inner hole dia. of filament picker reduced 18.03.2021 7 2 6 84
Testing at PDI from 1mm to 0.5mm in filament picker.
18.03.2021

06

Prepared By: Reviewed By:

Approved By:
Format No: F-ED-06
Process
Function
Step
Sealing & Exhausting:-
Stem after filament loading
auto load on m/c jig &
shell from vibrator to
sealing m/c jig. After
50 heating of stem from flare
side & shell from bottom
side sealing is done by
m/c spl assembly after that
all pieces are annealed by
passing throught a oven &
gas is fill in shell from ext.
tube which is cut after that
by flame.
100% visual inspection done for :
100% Visual Inspection mount bend, Wire burn, improper
51
done for visual dimentions sealing, Flare crack, Punch Crack,
Sealing crack, no hole, w/o Getter.
Cutting move to capping
52
m/c
Cap Embossing for bach
60
code on Machine
Moving of Embossing
61
base cap to Capping m/c
Mixing Cement moved to capping
Moving of Mixing Cement
71 machine in defined Cement Mixing
to Capping m/c
Pots.
Mixing of cement with
70
spirit by machine
Cement filled caps fit on cutting &
Capping :
temperature. Side wire of cap is bend
on cap surface & cut by cutter at a
80 Cement fillled cap fit on
fixed height, also top wire of cap is Pin to Top of Shell more than ( 45.0 mm Max)
cutting, bake in oven &
cut by cutter at a fixed height. After
top or side soldering done
on machine cutting side & top soldering is done on
81 100% visual inspection.
82 Move to Ageing
Ageing & Amp. Testing is
90 done on machine
automatically
Prepared By:
Rev No : 00 Eff. Dt. : 01.09.2014
Current Process Responsibilit Action Results
Classification
y
Detection
Occurrence
Occurrence
Severity
Actions
Detection
Potential Effect(s) of
Severity
RPN
Requirements Potential Failure Mode Potential Cause(s) of Failure Controls Recommended Actions Taken
RPN
Failure Controls Detection & Target
Prevention Completion Completion
Date Date
Total Length less then (37 ± 0.5 mm) LCL high 7 Shell holder wear out 3 3 63
Preventive Setup approvel+In
Maintenance process
Total Length more then (37 ± 0.5 mm) LCL less 7 Nozzle wear out 3 3 63
Setup approvel+In
Dia More then (14mm max) Torsion failure 6 High blowing Flow meter 3 4 72
process
LCL (After Capping) less then (30.8 ~ 32.8 mm) No effect 6 Sealing length high 3 Setup approvel 3 54
Stem is load on sealing m/c auto from LCL (After Capping) more then (30.8 ~ 32.8 mm) Black bulb 7 Sealing length less 3 4 84
conveyor & shell is load on same stem
jig from vibrator. Stem & shell is
Lateral Deviation
heated to a fix molten state of glass Bulb center out 7 Improper Sealing 3 Setup approvel 4 84
(After Capping)* (1.5 mm max) more
for sealing of stem & shell, after that
all pieces are annealed by pass from Angular Displacement Light direction change at Cutting direction out at threading
oven to a fix temp & time, mean time 6 3 Setup approvel 4 72
(After Capping)* (90 ± 15˚) more Customer end process
exhausting is done or gas is fill in
cutting from ext. tube & after gas Angular Displacement
filling unwanted ext. tube is cut by No effect
(After Capping)* (90 ± 15˚) less
flame. Preventive
Wire Burn Bulb not glow 7 Improper wire opening 4 3 84
maintenance
Improper sealing Milky Bulb 7 Improper melting Tem. Meter 4 3 84
Flare Crack Milky Bulb 7 Improper melting Tem. Meter 5 3 105
Punch Crack Milky Bulb 7 Improper anealing Tem. Meter 4 3 84
Sealing Crack Milky Bulb 7 Improper blowing Flow meter 4 3 84
No Hole in Sealing Milky Bulb 7 Less Blowing Flow meter 3 3 63
Defective Sample &
Mount Bend Bulb reject 8 Operator not inspection 3 3 72
W.I
Defective Sample &
Wire Burn Bulb reject 8 Operator not inspection 3 3 72
W.I
Defective Sample &
Improper sealing Bulb reject 8 Operator not inspection 3 3 72
W.I
Defective Sample &
Flare Crack Bulb reject 8 Operator not inspection 3 3 72
W.I
Defective Sample &
Punch Crack Bulb reject 8 Operator not inspection 3 3 72
W.I
Defective Sample &
Sealing Crack Bulb reject 8 Operator not inspection 3 3 72
W.I
Defective Sample &
No Hole Bulb reject 8 Operator not inspection 3 3 72
W.I
OK cutting are move in bins & not be
Material over loaded Material reject 6 3 3 54
over loaded
Embossing is done on cap for Model Appearance (Marking should be clearly visible) not Setup approvel+In
6 3 3 54
no , Tac no and Batch code visible process
Embossing Base caps moved to
Material over loaded Material reject 6 3 3 54
capping machine in defined bins
Cement over loaded
Cement come out of cap in next Std. not define for spirit & cement
Wrong Batch code emboss on cap operation of cap base filling 6 mixing 3 Setup approval 3 54
Mixing of cement ( Lamp Capping
Compound ) with Spirit & poured in
SS Pot in a recommended ratio. Mixer Cement mixture is thin. Torsion fail 7 3 Setup approval 3 63
run for 30 minutes to make it a
homogenous misture by machine
Cement & spirit ratio is not as specified Torsion fail 6 3 Setup approval 3 54
Length (52.5 mm Max) more No effect
bulb not fitted properly in soldering height more then Setup approvel+In
Pin to Solder Dim (7.5 mm Max) more 7 3 4 84
holder at customer end. (0.80mm) process
bulb not fitted properly in
Soldering Height less then ( 0.4 ~ 0.8 mm) 7 Less solder wire 3 4 84
holder at customer end.
Setup approvel+In
process
bake in oven at a defined Soldering Height more then ( 0.4 ~ 0.8 mm)
bulb not fitted properly in
7 More solder wire 3 3 63
holder at customer end.
No effect Cap not properly fitted in capsule Setup approvel
machine itself Setup approvel+In
Torsion less than (1.15 Nm Min) Torsion fail 7 Less qty. of cement & less baking 3 4 84
process
Setup approvel+In
Top & Side solder miss Bulb not glow 7 3 3 63
process
Additional assembly installed on
threading machine to separate lead in Prod
Lead in wire not separated properly Setup approvel+In
Lead in wire twist Double filament glow 7
during threading process - 3
process
5 105 wires. 07.02.20 07.02.20 8 2 6 96
05
100% visual insprction done for : side Side & Upper soldering 7 3 3 63
& upper soldering, Cap & Shell center Reject at final inspection Operator not inspection
out. cap & shell centre out 7 3 3 63
Bulbs, moved to Ageing & amp. Cap & shell centre out bulbs pass Bulb crack increase 6 3 3 54
Testing, kept in plastic bins having Bin
Card mentioning model name, date &
qty. Material not move in bins Material mixing increase 6 3 3 54
Test Voltage less then 13.5V current and lumen low 7 Power Supply failure 3 3 63
Test Voltage more more 13.5V current and lumen high 7 Power Supply failure 3 3 63
Poka - Yoke inbuilt in
machine in case voltage
Ageing & ampere testing is done by Current (Stop Filament) less then 0.67 ~ 0.81 Amp Light intensity low 7 Power Supply failure 3 out of specification then 3 63
Poka - Yoke
lamp glow 100% automatically on part will be detect and
Verification Sheet
machine at fix voltage. put separete bin
Current (Stop Filament) more then 0.67 ~ 0.81 Amp Light intensity high 7 Power Supply failure 3 3 63
automatically.
Setup approvel
Current (Top Filament) less then 0.41 ~ 0.49 Amp Light intensity low 7 Coiling length less 3 3 63
Current (Top Filament) more then 0.41 ~ 0.49 Amp Light intensity high 7 Coiling length more 3 3 63
Reviewed By:
Approved By:
Format No: F-ED-06 Rev No : 00 Eff. Dt. : 01.09.2014
Current Process Responsibilit Action Results

Classification
y

Detection
Occurrence

Occurrence
Severity
Actions

Detection
Process Potential Effect(s) of

Severity
RPN
Function Requirements Potential Failure Mode Potential Cause(s) of Failure Controls Recommended Actions Taken

RPN
Step Failure Controls Detection & Target
Prevention Completion Completion
Date Date
Firstly bulbs are packed in defined
Inner Cartons in a cardboard mesh. Bulbs don't get cooled in airy region. Bulbs damage 6 3 4 72
Carton taped, stickered, stamped with
Date Stamp & Model Stamp. These
100 Inner packing cartons are packed in an outer carton Bulbs are not packed in defined inner box. Qty mismatch with defined 7 Not aware about inner box. W.I 3 On the job training 3 63
& Slip is pasted on outer box for
model type or qty confermation. Inner box are not packed in defined outer cardboard
Bulb reject at customer end 7 Not aware about inner box. W.I 3 On the job training 3 63
box.

PDI done for all models before NG bulbs mixed with OK bulbs. Raised Customer Complaint 7 As per PDI Standard not checked PDI Standard 3 PDI 4 84
Bulb PDI done for all dispatch to any customer in defined
101
models PDI format & send to customer with
bill. PDI report not made & not send with bill Raised Customer Complaint 7 Lack of negligency 2 3 42

02 Material Special Finish Material not ready to

102 Despatch As per schedule Characterstics/Critical
not send as per schedule to Quality Impact Delivery Rating 7
dispatch
3 3 63

Note : 06
To prevent suction of impurities with filament, inner hole dia. of filament picker
18.03.2021 reduced from 1mm to 0.5mm in filament picker. Customer Complaint
02 Derived from customer Drawing/Engg. Specification
Additional assembly installed on threading machine to separate lead
Defined or Identified by Mithabhi 05 07.02.2020 in wires. Customer Complaint
M

Past Trouble 04 15.12.2018 Automatic filament loader vibrator covered with glass frame. Customer Complaint
PT
03 12.12.2017 Automatic filament loader installed in mount machine. Customer complaint

Process parameters added and symbol for special characteristics or critical to quality
02 27.09.2016 defined ,(PT) added. Customer complaint

01 12.04.2016 Inspection Frequency reduced after pre-launch control plan monitoring revised due to Customer complaint
production trial run.
00 30.06.2015 New Released as pre-launch Control Plan New Released
Rev No. ` Change Description Reason for Change Approval of customer (if Req.)

Prepared By: Reviewed By:

Approved By: