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SKH Metals Ltd.

Potential Failure Mode Effect Analysis
Process FMEA
Item (Part No) 85111-62S00 Customer Model Process Responsibility : FMEA NO. FMEA-85111-68P00

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Satyanarayan, krishan lal ,

Prep By
Maruti Sazuki India Limited pawan , rajesh , kaushal
RISER FR CUSH, OUTSIDE, RH Y1K HEAD (PRESS Shop.)
Krishana Maruti Ltd
Key Date

Date Original

Core Team : Mr. N.S. Rawat, Amit Bansal, Mukesh Sharma, Rakesh, BG, Pawan toor, Ankush, Ajay Manchanda, Harish Aggarwal, Vinod, Shiv Prakash, Dharampal, Vikram
Action Results
Process

Occurrence

Detection
Responsibility

Severity
Step

Occurrence
RPN
Class

Severity
Potential Effects(S) of Potential Causes(S) of Current Process Control Current Process Control Recommende & Target

Detection
Requirements Potential Failure Mode Action Taken

RPN
Failure Failure Prevention Detection d Actions Completion & Effective
Process Date Date
Function

Receipt Proper Material As Per Supplier audit for proper storage

Thickness variation Functional failure 6 S Matrl. Mixed at supplier end 2 Receipt Inspection 6 72
Inspection of Raw Specification and packaging
Material Material testing by
Correct material To be Wrong matrl. Supplied by Supplier Test certificate
Wrong material Component scrap 5 C 1 accrediated lab. (As per 6 72
Supplied supplier Verification
plan)
No Rust, Pitting marks
Rust, pitting marks etc. Poor appearance 5 S Packing not proper Raw matrl. Packaging std. 2 Visual inspection at Receipt. 7 56
etc.
Packet Condition (Proper
Packet Condition Should
Strapping with Metal / Plastic Material Damaged 4 S Packing not proper Raw matrl. Packaging std. 2 Visual inspection at Receipt. 7 56
be ok
Cover) Not ok

5 M Locators worn out & Loose Proper location of guide pins 3 5 75

Blank Profile & Dimn. Further operations may be Set up Approval & Patrolling
Blank NG
should be ok affected Inspection
5 M Strip may shift on feeding Tool Preventive Maintenance 4 5 100

Fitment
No Burr Burr Problem/Appearance NG 5 S Punch and Die clearance not ok Tool Preventive Maintenance 4 5 100
User may be injured
Set up Approval & Patrolling
5 S Sheet thickness not proper Tool Preventive Maintenance 4 5 100
Inspection

5 S Punch and Die worn out Tool Preventive Maintenance 4 5 100

Blanking
5 C Relieving not proper in die. Tool Preventive Maintenance 4 5 100
Further operations may be Set up Approval & Patrolling
No Deformation Deformation
affected Inspection
5 C Foreign material in die Tool Preventive Maintenance 4 5 100

No Dent Dent Poor appearance. 5 S Blank ejection not smooth Tool Preventive Maintenance 4 5 100

Set up Approval & Patrolling

5 S Foreign material in die Tool Preventive Maintenance 4 5 100
Inspection

5 S Loose bolts Tool Preventive Maintenance 4 5 100

Crack / Thinning free Component will fail

Crack / Thinning in part 5 C Improper draw clearance Tool Preventive Maintenance 4 Set up Approval 5 100
profile during next operation (s)

5 C High cushion pressure Operation std. 3 Set up Approval 5 75 ---

Raw material not as per Third party verification of Raw

5 C 3 Set up Approval 5 75
spec. Material

Few portion of the production Periodic (3 month) Checking of

5 C Unequal Cushion Pin Size 2 Set up approval 5 50
may have to be scrapped Pin Size

5 C Wrong cushion pin layout Operation std. 3 Set up approval 5 75

Tool Matching Surface Worn

5 C Tool Preventive Maintenance 4 Part check during setup 5 100
out
Parallelism NG (between
5 C Preventive Maint. 2 Part check during setup 5 50
upper & lower bed)
Set up Approval & Patrolling
Wrinkle free profile Wrinkle Fitment/ Appearance NG 5 S Less cushion pressure. Operation std. 3 5 75
Inspection
Periodic (3 month) Checking of
5 S Incorrect cushion pin height. 2 Set up approval 5 50
Pin Size
Unequal sizes of cushion Periodic (3 month) Checking of
5 S 2 Set up approval 5 50
pins. Pin Size

5 S Main pressure drop ------- 2 5 50

Tool Matching Surface Worn Set up Approval & Patrolling

5 S Tool Preventive Maintenance 4 Inspection 5 100
out

5 S Blank size short ------- 2 5 50

No Folding/ Overlapping Folding / Overlapping Appearance NG Tool Matching Surface Worn

Draw 4 S Tool Preventive Maintenance 4 5 80
out Set up Approval & Patrolling
Use only Standard Draw Oil & Inspection
4 S Improper Lubrication 1 5 20
proper frequency
Appearance/ strength Improper clearance between
No Scratch Scratch 5 S Preventive Maintenance of Tool 4 5 100
reduced upper & lower die
Air pressure gun for cleaning on Set up Approval & Patrolling
5 S Foreign material in die 2 5 50
the M/C Inspection

5 S Improper Lubrication Use only Standard Draw Oil 2 5 50

No Deformation Deformation Fitment/ Appearance NG 5 C Relieving not proper in die. Tool Preventive Maintenance 4 5 100

Raw Material TC Proper Set up Approval & Patrolling

5 C Raw material problem. 2 5 50
Packaging Inspection
Air pressure gun for cleaning on
5 C Foreign material in die 2 5 50
the M/C
Air pressure gun for cleaning on
No Dent Dent Appearance NG 5 S Foreign material in die 2 5 50
the M/C
Set up Approval & Patrolling
5 S Sheet thickness not proper Tool Preventive Maintenance 4 5 100
Inspection
 Page 2 of 3 Action Results
Process

Occurrence

Detection
Responsibility

Severity
Step

Occurrence
RPN
Class

Severity
Potential Effects(S) of Potential Causes(S) of Current Process Control Current Process Control Recommende & Target

Detection
Requirements Potential Failure Mode Action Taken

RPN
Failure Failure Prevention Detection d Actions Completion & Effective
Process Date
Set up Approval & Patrolling Date
Function
Inspection

5 S Tool Worn Out Preventive Maintenance of Tool 4 5 100

Component rejected in
No Draw Out Draw out 5 C Miss feed by operator Training to operator 2 5 50
next operation/fitment
problem Die Gauge/Blank locating pin Set up Approval & Patrolling
5 C Tool Preventive Maintenance 2 5 50
not proper Inspection

5 C Improper die surface Tool Preventive Maintenance 2 5 50

Draw height should be Set up Approval & Patrolling

Draw height NG Fitment/ Matching NG 8 C Less Stroke Length Die dead stopper provided 2 5 80
ok Inspection

Proper Flanging Swaging not proper Functional Problem 5 S Force inadequate Proper Die Height Setting 2 5 50

Profile location/Die gauging for

5 S Part location not proper 2 5 50
location Set up Approval & Patrolling
Inspection
Dimensional should be ok Dimensional problem Fitment problem 5 S Less stroke length Dead block provided 2 5 50
REST/ FL UP Component rejected in next
No Crack Crack 8 C Defective tooling Tool Preventive Maintenance 2 5 80
opreration

Proper restrike should be

Restrike less component Fitment/ Matching NG 5 C Less Stroke Length Die dead stopper provided 2 5 50
done

No Burr Burr Fitment 5 S Cutting edge of tool blunt. Tool Preventive Maintenance 4 5 100
Set up Approval & Patrolling
Problem/Appearance NG
Inspection
User may be injured 5 S Improper cutting clearance Tool Preventive Maintenance 4 5 100
Fitment
No Crack Crack Problem/Appearance NG 5 S Mismatch of cutting edge Tool Preventive Maintenance 4 5 100
User may be injured Set up Approval & Patrolling
Inspection
5 S Improper cutting clearance Tool Preventive Maintenance 4 5 100

Fitment Problem / Wear and tear of locating

Profile should be ok Profile NG 5 S Tool Preventive Maintenance 4 5 100
Customer dissatisfy pins /Stoppers Set up Approval & Patrolling
Inspection
5 S Punch worn out Tool Preventive Maintenance 4 5 100

Fitment Problem / Set up Approval & Patrolling

No trim short Trim short 5 M Location pin short Tool Preventive Maintenance 4 5 100
Customer dissatisfy Inspection
Proper Piercing With No User May Injured/ Fitment
Hole Burr 5 S Punch and Die clearance not ok Tool Preventive Maintenance 4 5 100
Burr Problem Set up Approval & Patrolling
Inspection
5 S Punch and Die worn out Tool Preventive Maintenance 4 5 100

Set up Approval & Patrolling

No Hole Miss Hole Miss 5 C Cam / Punch broken Tool Preventive Maintenance 4 5 100
Inspection

C-TRIM/ PIE Fitment Problem at next Training to operator & supervisor /

2 7 70
assembly shop / customer WIP tag initiated for WIP material
end Without operation material sent
5 C
to next shop
2 4 40

No Hole Oval Hole Oval Fitment Problem During 5 S Punch worn out Tool Preventive Maintenance 4 5 100
Next Operation or Final
Assembly 5 S Cam Angle/Position NG Tool Preventive Maintenance 4 5 100
Set up Approval & Patrolling
Wear and tear of locating Inspection
No Hole Shift Hole Shift May not be accepted by 5 S Tool Preventive Maintenance 4 5 100
pins /Stoppers
customer i.e. customer
dissatisfaction 5 S Cam Angle/Position NG Tool Preventive Maintenance 4 5 100

No Hole Over Size/ Under

Hole Over Size/ Under Size
Size
Fitment Problem During
Next Operation or Final
Assembly
5 S Punch under size /over size
5 S Burr folded inside
5 S Punch worn out
Tool Preventive Maintenance 4 5 100
Air pressure gun for cleaning on the Set up Approval & Patrolling
2 5 50
M/C Inspection
Tool Preventive Maintenance 4 5 100

Set up Approval & Patrolling

5 M Miss feed by operator Tool Preventive Maintenance 4 5 100
Inspection

Proper restrike should be

Restrike less component Fitment/ Matching NG 5 C Less Stroke Length Die dead stopper provided 2 5 50
done

5 S Punch and Die clearance not ok Tool Preventive Maintenance 4 5 100

Proper Piercing With No User May Injured/ Fitment Set up Approval & Patrolling
Hole Burr
Burr Problem Inspection
5 S Punch and Die worn out Tool Preventive Maintenance 4 5 100

Set up Approval & Patrolling

5 C Cam / Punch broken Tool Preventive Maintenance 4 5 100
Inspection

Fitment Problem at next Training to operator & supervisor /

2 7 70
No Hole Miss Hole Miss assembly shop / customer WIP tag initiated for WIP material
end Without operation material sent
5 C
to next shop
RESTRIKE & 2 4 40
PIERCING

Fitment Problem During 5 S Punch worn out Tool Preventive Maintenance 4 5 100
No Hole Oval Hole Oval Next Operation or Final
Assembly 5 S Cam Angle/Position NG Tool Preventive Maintenance 4 5 100
Set up Approval & Patrolling
Wear and tear of locating Inspection
May not be accepted by 5 S Tool Preventive Maintenance 4 5 100
pins /Stoppers
No Hole Shift Hole Shift customer i.e. customer
dissatisfaction 5 S Cam Angle/Position NG Tool Preventive Maintenance 4 5 100

Fitment Problem During 5 S Punch under size /over size Tool Preventive Maintenance 4 5 100
No Hole Over Size/ Under Set up Approval & Patrolling
Hole Over Size/ Under Size Next Operation or Final
Size Air pressure gun for cleaning on the Inspection
Assembly 5 S Burr folded inside 2 5 50
M/C
Proper restrike should be
CAM-REST Restrike less component Fitment/ Matching NG 5 C Less Stroke Length Die dead stopper provided 2 5 50
done
 Page 3 of 3 Action Results
Process

Occurrence

Detection
Responsibility

Severity
Step

Occurrence
RPN
Class

Severity
Potential Effects(S) of Potential Causes(S) of Current Process Control Current Process Control Recommende & Target

Detection
Requirements Potential Failure Mode Action Taken

RPN
Failure Failure Prevention Detection d Actions Completion & Effective
Process Date Date
Function

Proper Piercing With No User May Injured/ Fitment

Hole Burr 5 S Punch and Die clearance not ok Tool Preventive Maintenance 4 5 100
Burr Problem Set up Approval & Patrolling
Inspection
5 S Punch and Die worn out Tool Preventive Maintenance 4 5 100

Set up Approval & Patrolling

No Hole Miss Hole Miss 5 C Cam / Punch broken Tool Preventive Maintenance 4 5 100
Inspection

Fitment Problem at next Training to operator & supervisor /

2 7 70
assembly shop / customer WIP tag initiated for WIP material
end Without operation material sent
5 C
to next shop
2 4 40

No Hole Oval Hole Oval Fitment Problem During 5 S Punch worn out Tool Preventive Maintenance 4 5 100
Next Operation or Final
C-PIE/ PIE Assembly 5 S Cam Angle/Position NG Tool Preventive Maintenance 4 5 100
Set up Approval & Patrolling
Wear and tear of locating Inspection
No Hole Shift Hole Shift May not be accepted by 5 S Tool Preventive Maintenance 4 5 100
pins /Stoppers
customer i.e. customer
dissatisfaction 5 S Cam Angle/Position NG Tool Preventive Maintenance 4 5 100

No Hole Over Size/ Under

Hole Over Size/ Under Size 5 S Punch under size /over size Tool Preventive Maintenance 4 5 100
Size
Fitment Problem During
Air pressure gun for cleaning on the Set up Approval & Patrolling
Next Operation or Final 5 S Burr folded inside 2 5 50
M/C Inspection
Assembly
5 S Punch worn out Tool Preventive Maintenance 4 5 100

Set up Approval & Patrolling

5 M Miss feed by operator Tool Preventive Maintenance 4 5 100
Inspection

C - Critical Having Severity Between 8-10

M - Major Having Severity Between 7
S - Significant Having Severity Between 4-6 Control Stamp
Mn - Minor Having Severity Between 1-3 01
S.No Rev No. Description Date