Doc. No.

PDC-EPD-F03

PROCESS FAILURE MODE AND EFFECTS ANALYSIS Rev. No. (Date)00 (01/09/2019)

Issue No. (Date)02 (01/09/2019)

PFMEA Number 8941725283 FMEA-MCD-110-170 Key Contact / Phone Name / Works / Dept Team Member Department
Rev. No. (Date) 02(27/10/2021) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) 05.05.2017 Mr. Suraj Rawat GM- QA & QC
Part Number 8941725291 Mr. Pradeep garg GM- Operation
Process Responsibility: Core Team
Part Name / Description Flywheel ASM Mr. Arjun Yadav Manager Quality Machine Shop
Material Grade FC 230 Key Date : 5.May.17 Mr. Vineet Upadhyay Sr. Engineer QA

Current Process Controls Action Results

Proc Recomme Responsibili
Potential Failure
Process Function / Requirements ess Potential Effect(s) of Failure B. No S C Potential Cause(s) / Mechanism(s) of Failure O D RPN nded ty & Target
Mode
No. Actions Date
Prevention Detection Actions Taken S O D RPN

Rejection Increases,
More 6 Incorrect Set up of Fixture, loose 3 Set up Approval, In Process 5 90
Ø 50.8 / 51.2 Assembly Problems
Inner Diameter 1 Mounting/Clamping, Faulty Tool Travel , Process Controlled Inspection, Operator
mm Rework Increases,
Less 5 Tool Wear 3 Monitoring 5 75
Assembly Problems

Rejection Increases,
More 7 Incorrect Set up of Fixture, loose 3 Set up Approval, In Process 4 84
Ø 95.000 / Assembly Problems
Inner Diameter
95.040 mm
2 ●▼ Mounting/Clamping, Faulty Tool Travel , Process Controlled Inspection, Operator
Rework Increases, Tool Wear Monitoring,SPC Analysis
Less 7 3 4 84
Assembly Problems
110
Rework Increases,
More 5 Incorrect Set up of Fixture, loose 3 6 90
Outer Ø 110.7 / 111.3 Assembly Problems Set up Approval, In Process
3 Mounting/Clamping, Faulty Tool Travel , Program Controlled
Diameter mm Rejection Increases, Inspection
Less 5 Tool Wear 3 6 90
Assembly Problems

Rejection Increases,
More 5 Incorrect Set up of Fixture, loose 3 6 90
Ø 229.00 / Assembly Problems
Inner Diameter 4 Mounting/Clamping, Faulty Tool Travel , Pattern Controlled Set up Approval
232.00 mm Rework Increases,
Less 5 Tool Wear 3 6 90
Assembly Problems

Incorrect Set up of Fixture, loose 3 Set up Approval, Operator

Balancinh Ø 250.0 ± 0.50 Rejection Increases,
Hole PCD mm
150 More/Less
Assembly Problems
5 7 ▼ Mounting/Clamping, Faulty Tool Travel , Program Controlled Monitoring, In-Process 5 105
Tool Wear 3 Inspection

Rework Increases,
More 6 Incorrect Set up of Fixture, loose 3 Set up Approval, In Process 4 72
Ø 271.30 / Assembly Problems
Outer Diameter
271.40 mm
6 ●▼ Mounting/Clamping, Faulty Tool Travel , Process Controlled Inspection, Operator
Rejection Increases, Tool Wear Monitoring,SPC Analysis
Less 6 3 4 72
Assembly Problems
110
Rework Increases,
More 5 Incorrect Set up of Fixture, loose 3 6 90
Outer Ø 275.5 / 276.5 Assembly Problems
7 Mounting/Clamping, Faulty Tool Travel , Program Controlled Set up Approval
Diameter mm Rejection Increases,
Less 5 Tool Wear 3 6 90
Assembly Problems
Rework Increases,
More 5 Incorrect Set up of Fixture, loose 3 6 90
Outer Ø 296.70 / Assembly Problems Set up Approval, In Process
120 8 Mounting/Clamping, Faulty Tool Travel , Program Controlled
Diameter 297.30 mm Rejection Increases, Inspection
Less 5 Tool Wear 3 6 90
Assembly Problems
Rejection Increases,
Less 6 Incorrect Set up of Fixture, loose 3 6 108
16.50 / 18.00 Assembly Problems
Depth 9 Mounting/Clamping, Faulty Tool Travel , Process Controlled Set up Approval
mm Rework Increases,
More 5 Tool Wear 3 6 90
Assembly Problems

Incorrect Set up of Fixture, loose

Rejection Increases,
Radius R10 More 12 4 Mounting/Clamping, Faulty Tool Travel , 3 Program Controlled Set up Approval 7 84
Assembly Problems
Tool Wear

Rework Increases,
Less 4 Incorrect Set up of Fixture, loose 3 7 84
Assembly Problems
Chamfer 1.5 X 45° 110 13 Mounting/Clamping, Faulty Tool Travel , Program Controlled Set up Approval
Rejection Increases, Tool Wear
More 4 3 7 84
Assembly Problems

Incorrect Set up of Fixture, loose

Rejection Increases,
Radius R0.8 More 14 4 Mounting/Clamping, Faulty Tool Travel , 3 Program Controlled Set up Approval 7 84
Assembly Problems
Tool Wear

Incorrect Set up of Fixture, loose

Rejection Increases,
Angle 30° More / Less 15 7 Mounting/Clamping, Faulty Tool Travel , 3 Pattern Controlled 4 84
Assembly Problems
Tool Wear

1 of 8
 Doc. No. PDC-EPD-F03

PROCESS FAILURE MODE AND EFFECTS ANALYSIS Rev. No. (Date)00 (01/09/2019)

Issue No. (Date)02 (01/09/2019)

PFMEA Number 8941725283 FMEA-MCD-110-170 Key Contact / Phone Name / Works / Dept Team Member Department
Rev. No. (Date) 02(27/10/2021) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) 05.05.2017 Mr. Suraj Rawat GM- QA & QC
Part Number 8941725291 Mr. Pradeep garg GM- Operation
Process Responsibility: Core Team
Part Name / Description Flywheel ASM Mr. Arjun Yadav Manager Quality Machine Shop
Material Grade FC 230 Key Date : 5.May.17 Mr. Vineet Upadhyay Sr. Engineer QA

Current Process Controls Action Results

Proc Recomme Responsibili
Potential Failure
Process Function / Requirements ess Potential Effect(s) of Failure B. No S C Potential Cause(s) / Mechanism(s) of Failure O D RPN nded ty & Target
Mode
No. Actions Date
Prevention Detection Actions Taken S O D RPN

Incorrect Set up of Fixture, loose

Rejection Increases,
Radius R3.0 More 16 4 Mounting/Clamping, Faulty Tool Travel , 3 Program Controlled Set up Approval 7 84
Assembly Problems
Tool Wear

Rework Increases,
Less 5 Incorrect Set up of Fixture, loose 3 7 105
Assembly Problems
Chamfer 17 Mounting/Clamping, Faulty Tool Travel , Program Controlled Set up Approval
0.5 X 45° Rejection Increases,
More 5 Tool Wear 3 7 105
Assembly Problems

Incorrect Set up of Fixture, loose Program & Process

Rejection Increases, Set up Approval , Inprocess
Surface Finish 3.2 µRa More 18 5 Mounting/Clamping, Faulty Tool Travel , 3 Controlled , Tool 6 90
Assembly Problems Inspection
Tool Wear Life Monitoring

Incorrect Set up of Fixture, loose Program & Process

Rejection Increases,
Surface Finish 3.2 - 6.3 µRa More 19 5 Mounting/Clamping, Faulty Tool Travel , 3 Controlled , Tool Set up Approval 7 105
Assembly Problems
Tool Wear Life Monitoring

Incorrect Set up of Fixture, loose Program & Process

Rejection Increases,
Surface Finish 12.5 - 25 µRa 110 More 20 5 Mounting/Clamping, Faulty Tool Travel , 3 Controlled , Tool Set up Approval 7 105
Assembly Problems
Tool Wear Life Monitoring

Incorrect Set up of Fixture, loose Program & Process

Rejection Increases, Set up Approval , Inprocess
Surface Finish 3.2 - 6.3 µRa More 21 5 Mounting/Clamping, Faulty Tool Travel , 3 Controlled , Tool 7 105
Assembly Problems Inspection
Tool Wear Life Monitoring

Rework Increases,
Less 5 3 7 105
Assembly Problems Incorrect Set up of Fixture, loose
Chamfer 1.0 X 45° 22 Mounting/Clamping, Faulty Tool Travel , Program Controlled Set up Approval
Rejection Increases, Tool Wear
More 5 3 7 105
Assembly Problems

Incorrect Set up of Fixture, loose

Rejection Increases,
Radius R0.2/0.5 More 23 4 Mounting/Clamping, Faulty Tool Travel , 3 Program Controlled Set up Approval 7 84
Assembly Problems
Tool Wear

Incorrect Set up of Fixture, loose Program & Process

Rejection Increases, Set up Approval , Inprocess
Surface Finish 3.2 - 6.3 µRa More 24 5 Mounting/Clamping, Faulty Tool Travel , 3 Controlled , Tool 6 90
Assembly Problems Inspection
Tool Wear Life Monitoring

Incorrect Set up of Fixture, loose Program & Process

Rejection Increases,
Surface Finish 12.5 - 25 µRa 120 More 25 5 Mounting/Clamping, Faulty Tool Travel , 3 Controlled , Tool Set up Approval 7 105
Assembly Problems
Tool Wear Life Monitoring

2 of 8
 Doc. No. PDC-EPD-F03

PROCESS FAILURE MODE AND EFFECTS ANALYSIS Rev. No. (Date)00 (01/09/2019)

Issue No. (Date)02 (01/09/2019)

PFMEA Number 8941725283 FMEA-MCD-110-170 Key Contact / Phone Name / Works / Dept Team Member Department
Rev. No. (Date) 02(27/10/2021) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) 05.05.2017 Mr. Suraj Rawat GM- QA & QC
Part Number 8941725291 Mr. Pradeep garg GM- Operation
Process Responsibility: Core Team
Part Name / Description Flywheel ASM Mr. Arjun Yadav Manager Quality Machine Shop
Material Grade FC 230 Key Date : 5.May.17 Mr. Vineet Upadhyay Sr. Engineer QA

Current Process Controls Action Results

Proc Recomme Responsibili
Potential Failure
Process Function / Requirements ess Potential Effect(s) of Failure B. No S C Potential Cause(s) / Mechanism(s) of Failure O D RPN nded ty & Target
Mode
No. Actions Date
Prevention Detection Actions Taken S O D RPN

Rejection Increases,
Less 5 3 6 90
Assembly Problems
Incorrect Set up of Fixture, loose
Depth 4.7 / 6.2 mm 26 Mounting/Clamping, Faulty Tool Travel , Program Controlled Set up Approval
Tool Wear
Rework Increases,
More 5 3 6 90
Assembly Problems

Incorrect Set up of Fixture, loose

Rejection Increases,
Surface Finish 3.2 - 6.3 µRa More 27 4 Mounting/Clamping, Faulty Tool Travel , 3 Program Controlled Set up Approval 7 84
Assembly Problems
Tool Wear

Rejection Increases,
Less 6 3 5 90
Assembly Problems Incorrect Set up of Fixture, loose
Set up Approval, In Process
Depth 12.5 / 12.7 mm 110 28 ▼ Mounting/Clamping, Faulty Tool Travel , Program Controlled
Inspection
Rework Increases, Tool Wear
More 5 3 5 75
Assembly Problems

Rejection Increases,
Less 6 3 5 90
Assembly Problems Incorrect Set up of Fixture, loose
Set up Approval, In Process
Depth 1.40 / 1.60 mm 29 ▼ Mounting/Clamping, Faulty Tool Travel , Program Controlled
Inspection
Rework Increases, Tool Wear
More 5 3 5 75
Assembly Problems

Rejection Increases,
Less 6 3 5 90
Assembly Problems Incorrect Set up of Fixture, loose
Set up Approval, In Process
Depth 6.80 / 7.20 mm 30 Mounting/Clamping, Faulty Tool Travel , Program Controlled
Inspection
Rework Increases, Tool Wear
More 5 3 5 75
Assembly Problems

Rejection Increases,
Less 6 3 5 90
Assembly Problems Incorrect Set up of Fixture, loose
61.90 / 62.10 Set up Approval, In Process
Total Height 31 ▼ Mounting/Clamping, Faulty Tool Travel , Program Controlled
mm Inspection
Rework Increases, Tool Wear
More 6 3 5 90
Assembly Problems

Rejection Increases,
Less 6 Incorrect Set up of Fixture, loose 3 5 90
Assembly Problems Set up Approval, In Process
Depth 41.9 / 42.1 mm 32 ▼ Mounting/Clamping, Faulty Tool Travel , Program Controlled
Inspection
Rework Increases, Tool Wear
More 6 3 5 90
Assembly Problems

Rejection Increases,
Less 5 Incorrect Set up of Fixture, loose 3 6 90
Assembly Problems
Depth 7.8 / 8.2 mm 33 Mounting/Clamping, Faulty Tool Travel , Program Controlled Set up Approval
Rework Increases, Tool Wear
More 5 3 6 90
120 Assembly Problems
Rejection Increases,
Less 5 Incorrect Set up of Fixture, loose 3 6 90
33.70 / 34.30 Assembly Problems
Depth 34 Mounting/Clamping, Faulty Tool Travel , Program Controlled Set up Approval
mm Rework Increases,
More 5 Tool Wear 3 6 90
Assembly Problems
Rejection Increases,
Less 5 Incorrect Set up of Fixture, loose 3 6 90
Assembly Problems
Depth 17.3 / 17.8 mm 35 Mounting/Clamping, Faulty Tool Travel , Program Controlled Set up Approval
Rework Increases, Tool Wear
More 5 3 6 90
Assembly Problems
Rejection Increases,
Less 5 Incorrect Set up of Fixture, loose 3 6 90
Assembly Problems Set up Approval, In Process
Width 15.3 / 15.7 mm 36 Mounting/Clamping, Faulty Tool Travel , Program Controlled
Rework Increases, Inspection
More 5 Tool Wear 3 6 90
Assembly Problems

3 of 8
 Doc. No. PDC-EPD-F03

PROCESS FAILURE MODE AND EFFECTS ANALYSIS Rev. No. (Date)00 (01/09/2019)

Issue No. (Date)02 (01/09/2019)

PFMEA Number 8941725283 FMEA-MCD-110-170 Key Contact / Phone Name / Works / Dept Team Member Department
Rev. No. (Date) 02(27/10/2021) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) 05.05.2017 Mr. Suraj Rawat GM- QA & QC
Part Number 8941725291 Mr. Pradeep garg GM- Operation
Process Responsibility: Core Team
Part Name / Description Flywheel ASM Mr. Arjun Yadav Manager Quality Machine Shop
Material Grade FC 230 Key Date : 5.May.17 Mr. Vineet Upadhyay Sr. Engineer QA

Current Process Controls Action Results

Proc Recomme Responsibili
Potential Failure
Process Function / Requirements ess Potential Effect(s) of Failure B. No S C Potential Cause(s) / Mechanism(s) of Failure O D RPN nded ty & Target
Mode
No. Actions Date
Prevention Detection Actions Taken S O D RPN

Incorrect Set up of Fixture, loose Program & Process

Rejection Increases,
Surface Finish 3.2 - 6.3 µRa More 37 5 Mounting/Clamping, Faulty Tool Travel , 3 Controlled , Tool Set up Approval 7 105
Assembly Problems
Tool Wear Life Monitoring

Incorrect Set up of Fixture, loose Program & Process

Rejection Increases, Set up Approval, In Process
Surface Finish 3.2 - 6.3 µRa More 38 6 Mounting/Clamping, Faulty Tool Travel , 3 Controlled , Tool 6 108
Assembly Problems Insppection
Tool Wear Life Monitoring

Incorrect Set up of Fixture, loose

Rejection Increases,
Groove Depth 0.0 -1.0 mm More 39 5 Mounting/Clamping, Faulty Tool Travel , 3 Program Controlled Set Up Approval 7 105
120 Assembly Problems
Tool Wear

0.07 TIR MAX.

Rejection Increases, Dents in Jaws, Chips b/w butting area and Program & Process
Parallesim with Ref. 'C' on More
Assembly Problems
40 7 ▼ jaws
3
Controlled
Set Up Approval/ 1/Shift 6 126
Ø 225 mm

Incorrect Set up of Fixture, loose Program & Process

Rejection Increases,
Surface Finish 12.5 - 25 µRa More 41 5 Mounting/Clamping, Faulty Tool Travel , 3 Controlled , Tool Set up Approval 7 105
Assembly Problems
Tool Wear Life Monitoring

Rejection Increases,
Less 6 Incorrect Set up of Fixture, loose 3 6 108
9.80 / 10.20 Assembly Problems
Ream Depth 130 42 Mounting/Clamping, Faulty Tool Travel , Program Controlled Set up Approval
mm Rework Increases,
More 5 Tool Wear 3 6 90
Assembly Problems

Incorrect Set up of Fixture, loose Program & Process

Rejection Increases,
Surface Finish 12.5 - 25 µRa 120 More 43 5 Mounting/Clamping, Faulty Tool Travel , 3 Controlled , Tool Set up Approval 7 105
Assembly Problems
Tool Wear Life Monitoring

Rejection Increases,
Less 6 Incorrect Set up of Fixture, loose 3 6 108
13.80 /14.20 Assembly Problems
Drill Depth 130 44 Mounting/Clamping, Faulty Tool Travel , Program Controlled Set up Approval
mm Rework Increases,
More 6 Tool Wear 3 6 108
Assembly Problems

Incorrect Set up of Fixture, loose Program & Process

Rejection Increases, Set up Approval , Inprocess
Surface Finish 3.2 - 6.3 µRa More 45 5 Mounting/Clamping, Faulty Tool Travel , 3 Controlled , Tool 6 90
Assembly Problems Inspection
Tool Wear Life Monitoring

Rejection Increases,
More 5 Incorrect Set up of Fixture, loose 3 7 105
Ø 117.7 / 118.3 Assembly Problems
Inner Diameter 46 Mounting/Clamping, Faulty Tool Travel , Program Controlled Set up Approval
mm Rework Increases,
Less 5 Tool Wear 3 7 105
Assembly Problems
Rejection Increases,
More 6 Incorrect Set up of Fixture, loose 3 6 108
Ø 135.50 / Assembly Problems
Inner Diameter 47 Mounting/Clamping, Faulty Tool Travel , Pattern Controlled Set up Approval
136.50 mm 120
Rework Increases, Tool Wear
Less 6 3 6 108
Assembly Problems
Rejection Increases,
More 6 Incorrect Set up of Fixture, loose 3 6 108
Ø 149.0 / Assembly Problems
Inner Diameter 48 Mounting/Clamping, Faulty Tool Travel , Program Controlled Set up Approval
151.00 mm Rework Increases,
Less 6 Tool Wear 3 6 108
Assembly Problems

Rejection Increases,
More 6 Incorrect Set up of Fixture, loose 3 6 108
Groove Inner Ø 229.5 / 230.5 Assembly Problems
49 Mounting/Clamping, Faulty Tool Travel , Program Controlled Program Controlled
Diameter mm Rework Increases,
Less 6 Tool Wear 3 6 108
Assembly Problems

4 of 8
 Doc. No. PDC-EPD-F03

PROCESS FAILURE MODE AND EFFECTS ANALYSIS Rev. No. (Date)00 (01/09/2019)

Issue No. (Date)02 (01/09/2019)

PFMEA Number 8941725283 FMEA-MCD-110-170 Key Contact / Phone Name / Works / Dept Team Member Department
Rev. No. (Date) 02(27/10/2021) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) 05.05.2017 Mr. Suraj Rawat GM- QA & QC
Part Number 8941725291 Mr. Pradeep garg GM- Operation
Process Responsibility: Core Team
Part Name / Description Flywheel ASM Mr. Arjun Yadav Manager Quality Machine Shop
Material Grade FC 230 Key Date : 5.May.17 Mr. Vineet Upadhyay Sr. Engineer QA

Current Process Controls Action Results

Proc Recomme Responsibili
Potential Failure
Process Function / Requirements ess Potential Effect(s) of Failure B. No S C Potential Cause(s) / Mechanism(s) of Failure O D RPN nded ty & Target
Mode
No. Actions Date
Prevention Detection Actions Taken S O D RPN

Rejection Increases,
More 6 Incorrect Set up of Fixture, loose 3 5 90
Ø 234.5 / 235.5 Assembly Problems Set up Approval, In Process
Inner Diameter 50 Mounting/Clamping, Faulty Tool Travel , Program Controlled
mm Rework Increases, Inspection
Less 6 Tool Wear 3 5 90
Assembly Problems
120
Rework Increases,
More 6 Incorrect Set up of Fixture, loose 3 5 90
Outer Ø 290.5 / 291.5 Assembly Problems
51 Mounting/Clamping, Faulty Tool Travel , Program Controlled Set up Approval
Diameter mm Rejection Increases,
Less 6 Tool Wear 3 5 90
Assembly Problems
Rework Increases,
Less 5 Incorrect Set up of Fixture, loose 3 7 105
Assembly Problems
Chamfer 130 52 Mounting/Clamping, Faulty Tool Travel , Program Controlled Set up Approval
0.5 X 45° Rejection Increases,
More 5 Tool Wear 3 7 105
Assembly Problems

53 Incorrect Set up of Fixture, loose

Rejection Increases,
Radius R3.0 More & 5 Mounting/Clamping, Faulty Tool Travel , 2 Pattern Controlled Set up Approval 6 60
Assembly Problems
54 Tool Wear

55 Incorrect Set up of Fixture, loose Program & Process

Rejection Increases,
Surface Finish 12.5 - 25 µRa 120 More & 5 Mounting/Clamping, Faulty Tool Travel , 3 Controlled , Tool Set up Approval 7 105
Assembly Problems
56 Tool Wear Life Monitoring

Incorrect Set up of Fixture, loose

Rejection Increases,
Angle 2° More / Less 57 5 Mounting/Clamping, Faulty Tool Travel , 3 Program Controlled Program Controlled 7 105
Assembly Problems
Tool Wear

Incorrect Set up of Fixture, loose

Drill Dia
More Rejection Increases 4 Mounting/Clamping, Faulty Tool Travel , 3 Process Controlled Set up Approval 4 48
ɸ12.70 Max
Tool Wear
Incorrect Set up of Fixture, loose
Drill Depth
150 More Rejection Increases 58 4 Mounting/Clamping, Faulty Tool Travel , 3 Process Controlled Set up Approval 4 48
22.00 Max.
Tool Wear
Incorrect Set up of Fixture, loose
Wall Thickness 20.0mm Min. Less Rejection Increases 4 Mounting/Clamping, Faulty Tool Travel , 3 Process Controlled Set up Approval 4 48
Tool Wear

67 Incorrect Set up of Fixture, loose Set up Approval , In process

Center 62.70 / 62.80 Rejection Increases, Program & Process
Distance mm
More / Less
Assembly Problems
& 7 ▼ Mounting/Clamping, Faulty Tool Travel , 3
Controlled
inspection ,Operator 5 105
71 Tool Wear Monitoring

68 Incorrect Set up of Fixture, loose Set up Approval , In process

Center 108.640 / Rejection Increases, Program & Process
Distance 108.740 mm
More / Less
Assembly Problems
& 7 ▼ Mounting/Clamping, Faulty Tool Travel , 3
Controlled
inspection ,Operator 5 105
69 Tool Wear Monitoring

130
Incorrect Set up of Fixture, loose
Center Rejection Increases, Program & Process Set up Approval, CMM
134.70 Ref. More / Less 70 6 Mounting/Clamping, Faulty Tool Travel , 3 6 108
Distance Assembly Problems Controlled Inspection
Tool Wear

Incorrect Set up of Fixture, loose Set up Approval , In process

Center 125.45 / 125.55 Rejection Increases, Program & Process
Distance mm
More / Less
Assembly Problems
72 7 ▼ Mounting/Clamping, Faulty Tool Travel , 3
Controlled
inspection ,Operator 5 105
Tool Wear Monitoring

5 of 8
 Doc. No. PDC-EPD-F03

PROCESS FAILURE MODE AND EFFECTS ANALYSIS Rev. No. (Date)00 (01/09/2019)

Issue No. (Date)02 (01/09/2019)

PFMEA Number 8941725283 FMEA-MCD-110-170 Key Contact / Phone Name / Works / Dept Team Member Department
Rev. No. (Date) 02(27/10/2021) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) 05.05.2017 Mr. Suraj Rawat GM- QA & QC
Part Number 8941725291 Mr. Pradeep garg GM- Operation
Process Responsibility: Core Team
Part Name / Description Flywheel ASM Mr. Arjun Yadav Manager Quality Machine Shop
Material Grade FC 230 Key Date : 5.May.17 Mr. Vineet Upadhyay Sr. Engineer QA

Current Process Controls Action Results

Proc Recomme Responsibili
Potential Failure
Process Function / Requirements ess Potential Effect(s) of Failure B. No S C Potential Cause(s) / Mechanism(s) of Failure O D RPN nded ty & Target
Mode
No. Actions Date
Prevention Detection Actions Taken S O D RPN

Incorrect Set up of Fixture, loose 3 Set up Approval, Operator

Rejection Increases,
PCD Ø 74.00 mm More/Less
Assembly Problems
73 7 ▼ Mounting/Clamping, Faulty Tool Travel , Program Controlled Monitoring, In-Process 5 105
Tool Wear 3 Inspection

Incorrect Set up of Fixture, loose

Rejection Increases,
Radius R120.0 mm More / Less 74 4 Mounting/Clamping, Faulty Tool Travel , 3 Program Controlled Program Controlled 7 84
Assembly Problems
Tool Wear

Incorrect Set up of Fixture, loose 3 Set up Approval, Operator

Rejection Increases,
PCD Ø 251.00 mm More/Less
Assembly Problems
75 7 ▼ Mounting/Clamping, Faulty Tool Travel , Program Controlled Monitoring, In-Process 5 105
Tool Wear 3 Inspection

Incorrect Set up of Fixture, loose

Rejection Increases, Set up Approval, CMM
Angle 13.50° More / Less 76 6 Mounting/Clamping, Faulty Tool Travel , 3 Program Controlled 6 108
Assembly Problems Inspection
Tool Wear

Incorrect Set up of Fixture, loose Set up Approval, Operator

Rejection Increases,
Angle 73°20' / 73°40' More / Less
Assembly Problems
77 6 ▼ Mounting/Clamping, Faulty Tool Travel , 3 Program Controlled Monitoring, In-Process 5 90
Tool Wear Inspection

78 Incorrect Set up of Fixture, loose

Rejection Increases,
Angle 120 ° More / Less & 5 Mounting/Clamping, Faulty Tool Travel , 3 Program Controlled Set up Approval 6 90
Assembly Problems
79 Tool Wear

130 Rejection Increases,

More 7 Incorrect Set up of Fixture, loose Set up Approval, Operator
Mounting Hole Ø 13.35 / 13.65 Assembly Problems
Dia. mm
80 ▼ Mounting/Clamping, Faulty Tool Travel , 3 Program Controlled Monitoring, In-Process 5 105
Rework Increases, Tool Wear Inspection
Less 7
Assembly Problems

Rejection Increases,
Over Size 7 3 Process Set up Approval , In process 5
Assembly Problems
6 Tap Holes M8 X 1.25 ▼ Faulty tool travel, Tool Wear, Tool Run out Controlled & Tool inspection ,Operator 105
Rework increases, Life Study Monitoring
Under Size 7 3 5
Assembly Problems

Incorrect Set up of Fixture, loose 3 6 126

Rejection Increases, Set up Approval , In process
Tap Depth 16.0 mm Min. More / Less 7 Mounting/Clamping, Faulty Tool Travel , Program Controlled
Assembly Problems inspection
Tool Wear
3 6 0
81

Incorrect Set up of Fixture, loose 3 6 126

Rejection Increases, Set up Approval , In process
Drill Depth 20.0 mm Min. More / Less 7 Mounting/Clamping, Faulty Tool Travel , Program Controlled
Assembly Problems inspection
Tool Wear
3 6 0

Rework Increases,
Less 5 Incorrect Set up of Fixture, loose 3 7 105
Assembly Problems
Chamfer 90° Ø 8.5 Mounting/Clamping, Faulty Tool Travel , Program Controlled Set up Approval
Rejection Increases, Tool Wear
More 5 3 7 105
Assembly Problems

Rejection Increases,
More 6 Incorrect Set up of Fixture, loose 3 Set up Approval, In Process 5
3 Dowel Hole Ø 5.974 / 5.988 Assembly Problems
Dia. mm
82 ▼ Mounting/Clamping, Faulty Tool Travel , Process Controlled Inspection, Operator 90
Rework Increases, Tool Wear Monitoring
Less 6 3 5
Assembly Problems

6 of 8
 Doc. No. PDC-EPD-F03

PROCESS FAILURE MODE AND EFFECTS ANALYSIS Rev. No. (Date)00 (01/09/2019)

Issue No. (Date)02 (01/09/2019)

PFMEA Number 8941725283 FMEA-MCD-110-170 Key Contact / Phone Name / Works / Dept Team Member Department
Rev. No. (Date) 02(27/10/2021) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) 05.05.2017 Mr. Suraj Rawat GM- QA & QC
Part Number 8941725291 Mr. Pradeep garg GM- Operation
Process Responsibility: Core Team
Part Name / Description Flywheel ASM Mr. Arjun Yadav Manager Quality Machine Shop
Material Grade FC 230 Key Date : 5.May.17 Mr. Vineet Upadhyay Sr. Engineer QA

Current Process Controls Action Results

Proc Recomme Responsibili
Potential Failure
Process Function / Requirements ess Potential Effect(s) of Failure B. No S C Potential Cause(s) / Mechanism(s) of Failure O D RPN nded ty & Target
Mode
No. Actions Date
Prevention Detection Actions Taken S O D RPN

Rejection Increases,
Radius R3.0 More 83 4 Pattern Wear Out 2 Pattern Controlled Set up Approval 7 56
Assembly Problems

Rejection Increases,
Radius R3.0 More 84 4 Pattern Wear Out 2 Pattern Controlled Set up Approval 7 56
Assembly Problems

Dimension (2.0) mm More / Less Rejection Increase 85 4 Pattern Wear Out 2 Pattern Controlled Set up Approval 7 56

Incorrect Set up of Fixture, loose

Rejection Increases,
Radius R3.0 More 86 4 Mounting/Clamping, Faulty Tool Travel , 2 Pattern Controlled Set up Approval 7 56
Assembly Problems
Tool Wear

Rejection Increases,
Radius R18.0 More 87 4 Pattern Wear Out 2 Pattern Controlled Set up Approval 7 56
Assembly Problems

43.00 / 47.00 130 Rejection Increases,

Dimension More / Less 88 5 Pattern Wear Out 3 Pattern Controlled Set Up Approval 7 105
mm Assembly Problems

18.50 / 21.50 Rejection Increases,

Dimension More / Less 89 5 Pattern Wear Out 3 Pattern Controlled Set Up Approval 7 105
mm Assembly Problems

Rejection Increases,
Angle 15° More / Less 90 4 Pattern Wear Out 3 Pattern Controlled Set Up Approval 7 84
Assembly Problems

Rejection Increases,
Less 5 Incorrect Set up of Fixture, loose 3 6 90
Assembly Problems
Depth 6.80 / 9.20 mm 91 Mounting/Clamping, Faulty Tool Travel , Program Controlled Set up Approval
Rework Increases, Tool Wear
More 5 3 6 90
Assembly Problems

Rejection Increases,
Less 5 Incorrect Set up of Fixture, loose 3 5 75
16.80 / 19.20 Assembly Problems Set up Approval, In-Process
Depth 92 Mounting/Clamping, Faulty Tool Travel , Program Controlled
mm Rework Increases, Inspection
More 5 Tool Wear 3 5 75
Assembly Problems

Chamfered Side Of Ring Gear

Set Up Approval, Operator
Teeth Down Side Rejection Increase N/A. 7 Operator Negligence 3 Work Instruction 4 84
monitoring
To Be on Top Side

Less Assembly Problem 7 2 Temperature 4 56

Induction Heater Temperature Sensor setting not proper, Sensor showing Control Meter, Set Up Approval & Operator
140˚ - 150˚ C Changes in Chemical and
N/A. ▼ wrong reading Calibration of Monitoring
140 More 7 2 4 56
Mechanical Properties Digital meter

Assembly Problem, Rework

Less 7 2 4 56
Increase
Pressing Load Operator Negligence/ gauge Malfunction/ Set UP Approval & Operator
49 KN/5 Ton Crack Problem & Rejection
N/A. ▼ Equipment Malfunction
Trained Operator
Monitoring
More 7 2 4 56
Increase

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 Doc. No. PDC-EPD-F03

PROCESS FAILURE MODE AND EFFECTS ANALYSIS Rev. No. (Date)00 (01/09/2019)

Issue No. (Date)02 (01/09/2019)

PFMEA Number 8941725283 FMEA-MCD-110-170 Key Contact / Phone Name / Works / Dept Team Member Department
Rev. No. (Date) 02(27/10/2021) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) 05.05.2017 Mr. Suraj Rawat GM- QA & QC
Part Number 8941725291 Mr. Pradeep garg GM- Operation
Process Responsibility: Core Team
Part Name / Description Flywheel ASM Mr. Arjun Yadav Manager Quality Machine Shop
Material Grade FC 230 Key Date : 5.May.17 Mr. Vineet Upadhyay Sr. Engineer QA

Current Process Controls Action Results

Proc Recomme Responsibili
Potential Failure
Process Function / Requirements ess Potential Effect(s) of Failure B. No S C Potential Cause(s) / Mechanism(s) of Failure O D RPN nded ty & Target
Mode
No. Actions Date
Prevention Detection Actions Taken S O D RPN

Assembly Problem, Rework

Ring Gear Pressing Holding Less 7 2 Pressing Control 4 56
Increase Operator Negligence/ gauge Malfunction/ Set Up Approval & 100%
Dwell Time N/A. ▼ Equipment Malfunction
Unit & Operator
Monitoring
Min. 10 Sec. Crack Problem & Rejection Monitoring
More 7 2 4 56
Increase
140

Gap Between Shoulder & Face Work Instruction,

Set Up Approval, , Operator
of Ring Gap Rework Increases N/A. 7 ▼ Operator Negligence 2 Training Provided
monitoring, Final Inspection
4 56
0.100 to operator

Set up Approval, In Process

Unbalance Mass
150 More Rejection Increases 15B 4 Operator Negligence 3 Process Controlled Inspection, Operator 4 48
20 gr-cm
Monitoring

Cleaning Of Parts
Surface and Holes of the part
Chips & Rust Re Clean & Oiling N/A 4 Operator Negligence 3 Process Controlled Supervisor Monitoring 6 72
should be dry and free from
the Rust & Chips
160

RPO Filter Frequency Unclean Oil, Dust can stick

Not changed N/A 5 Operator Negligence 3 Process Controlled Supervisor Monitoring 6 90
7 days to holes

Packing
Mishandling Part may get damage N/A 5 Operator Negligence/ Part fall down 3 Trained Operator Supervisor Monitoring 6 90
Single line flow

170

Packing Standard &

Packing Quantity Per Box Less or More Supply NA 7 Operator Negligence 3 Process Controlled 2 42
Supervisor Monitoring

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