Doc. No.

PDC-EPD-F03

FAILURE MODE AND EFFECTS ANALYSIS Rev. No. (Date) 00 (01/01/2014)

Issue No. (Date) 04 (01/01/2014)

PFMEA Number : D10414410A-FMEA-CAS-01 Key Contact / Phone Name / Works / Dept Team Member Deparment
Revision No. (Date) : 00(03/10/2015) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) : 03/10/2015 Mr. Himanshu Duniwal PC
Part Number : D10414410A Mr. Mahesh Badaya DGM - Purchase
Process Responsibility: Core Team
Part Name / Description : Flywheel EURO 4550 DC Mr. Samadar Singh Manager - Casting
Material Grade : FG 260 Key Date : 3-Oct-15 Mr. Dhananjay Rai Manager - M/C Shop

Current Process Controls Action Results

Process Cause(s) / Mechanism(s) of Recommended Responsibility
Process Function / Requirements Failure Mode Effect(s) of Failure B. No. S C O D RPN
Failure Actions & Target Datre
Prevention Detection Actions Taken S O D RPN

60
Wrong Chemical
Undesired Chemical composition. Resulting in Supply of Wrong Composition Sampling Test Every
Pig Iron 6 2 Supplier Approval 5
Properties Non Conforming material Lot
properties
Receiving
Material 70
Wrong Chemical
Undesired composition. Resulting in Sampling Test Every
Other Additives 7 Supply of Wrong material 2 Supplier Approval 5
Properties Non Conforming Lot
properties

60
Sand Preparation as per
Low Cut & Washes 6 Drop in Clay Addition, Extra Mulling 2 5
Work Instruction
Sand Testing - One
Moisture
Batch Every Heat 60
Pin Holes& Rough Increase in Clay Addition, Insufficient Sand Preparation as per
Higher 6 2 5
Surface Mulling Work Instruction

60
Poor Finish, Burn in, Sand of Finer Grain Used, Improper Sand Preparation as per
Low 6 2 5
Penetration mixing of sand & Additives Work Instruction
Sand Testing - One
Sand Permeability
Batch Every Heat 60
Preparation
Sand of Rounded Grain Used, Sand Preparation as per
Higher Less Smooth Surface 6 2 5
Improper mixing of sand & Additives Work Instruction

60
Drop in Clay Addition, Decrease in
Sand Preparation as per Sand Testing - One
Low Drop in Clay 6 Sand to Metal Ratio, Less Fines, 2 5
Work Instruction Batch Every Heat
Insufficient Mulling etc
Sand Strength
90
Increase in Clay Addition, Increase in
Sand Preparation as per Sand Testing - One
Higher Increase in Clay 6 Sand to Metal Ratio, More Fines, 3 5
Work Instruction Batch Every Heat
Extra Mulling etc

64
Casting Rework & Visual Inspection of
Heat Codes Missing 4 Operator Negligence 2 Sampling Inspection 8
Punching Patterns

60
Mould Improper Sand Preparation &
Mould Hardness Low Extra Material 6 2 Inprocess Inspection Sampling Inspection 5
Making Ramming

72
Inspection of Patterns,
Broken Pattern, Improper Box
Appearance Broken Cavity Defective Casting 6 2 Proper Setting of Box & Sampling Inspection 6
Setting, Improper Ramming
Proper Ramming

1 of 7
 Doc. No. PDC-EPD-F03

FAILURE MODE AND EFFECTS ANALYSIS Rev. No. (Date) 00 (01/01/2014)

Issue No. (Date) 04 (01/01/2014)

PFMEA Number : D10414410A-FMEA-CAS-01 Key Contact / Phone Name / Works / Dept Team Member Deparment
Revision No. (Date) : 00(03/10/2015) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) : 03/10/2015 Mr. Himanshu Duniwal PC
Part Number : D10414410A Mr. Mahesh Badaya DGM - Purchase
Process Responsibility: Core Team
Part Name / Description : Flywheel EURO 4550 DC Mr. Samadar Singh Manager - Casting
Material Grade : FG 260 Key Date : 3-Oct-15 Mr. Dhananjay Rai Manager - M/C Shop

Current Process Controls Action Results

Process Cause(s) / Mechanism(s) of Recommended Responsibility
Process Function / Requirements Failure Mode Effect(s) of Failure B. No. S C O D RPN
Failure Actions & Target Datre
Prevention Detection Actions Taken S O D RPN

60
Improper Sand Preparation &
Core Hardness Low Extra Material 6 2 Inprocess Inspection Sampling Inspection 5
Ramming

Core Making 60
Inspection of Patterns,
Broken Pattern, Improper Box
Appearance Broken Core Defective Casting 6 2 Proper Setting of Box & Sampling Inspection 5
Setting, Improper Ramming
Proper Ramming

70
High Lost in Properties 7 Improper Charge Mixing 2 CE Test Sampling Test 5

CE
70
Low Lost in Properties 7 Improper Charge Mixing 2 CE Test Sampling Test 5
Melting &
Pouring 70
High Lost in Properties 7 Operator's Negligence 2 100 % Monitoring Sampling Test 5
Pouring
Temperature &
Time 70
Low Lost in Properties 7 Operator's Negligence 2 100 % Monitoring Sampling Test 5

32
High Lost in Properties 8 Operator's Negligence 2 100 % Monitoring Sampling Test 2

Knock Out Knock Out Time

32
Low Lost in Properties 8 Operator's Negligence 2 100 % Monitoring Sampling Test 2

70
Excessive Pitting over Surface 7 More Blasting Time 2 Inprocess Inspection Visual Inspection 5

Shot Blasting Blasting

70
Poor Loose Sand 7 Less Blasting Time 2 Inprocess Inspection Visual Inspection 5

48
More Grinding Force, More Grinding
Excessive Shape Lost 4 2 Inprocess Inspection Visual Inspection 6
Cut, Unskilled Operator
Grinding
Grinding
Process

2 of 7
 Doc. No. PDC-EPD-F03

FAILURE MODE AND EFFECTS ANALYSIS Rev. No. (Date) 00 (01/01/2014)

Issue No. (Date) 04 (01/01/2014)

PFMEA Number : D10414410A-FMEA-CAS-01 Key Contact / Phone Name / Works / Dept Team Member Deparment
Revision No. (Date) : 00(03/10/2015) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) : 03/10/2015 Mr. Himanshu Duniwal PC
Part Number : D10414410A Mr. Mahesh Badaya DGM - Purchase
Process Responsibility: Core Team
Part Name / Description : Flywheel EURO 4550 DC Mr. Samadar Singh Manager - Casting
Material Grade : FG 260 Key Date : 3-Oct-15 Mr. Dhananjay Rai Manager - M/C Shop

Current Process Controls Action Results

Process Cause(s) / Mechanism(s) of Recommended Responsibility
Process Function / Requirements Failure Mode Effect(s) of Failure B. No. S C O D RPN
Failure Actions & Target Datre
Prevention Detection Actions Taken S O D RPN
Grinding
Grinding
Process 48
Old / Broken Grinding Wheel, Less
Excessive Material
Poor 4 Grinding Force, Less Grinding Cut, 2 Inprocess Inspection Visual Inspection 6
Remained
Unskilled Operator

3 of 7
 Doc. No. PDC-EPD-F03

FAILURE MODE AND EFFECTS ANALYSIS Rev. No. (Date) 00 (01/01/2014)

Issue No. (Date) 04 (01/01/2014)

PFMEA Number : D10414410A-FMEA-CAS-01 Key Contact / Phone Name / Works / Dept Team Member Deparment
Revision No. (Date) : 00(03/10/2015) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) : 03/10/2015 Mr. Himanshu Duniwal PC
Part Number : D10414410A Mr. Mahesh Badaya DGM - Purchase
Process Responsibility: Core Team
Part Name / Description : Flywheel EURO 4550 DC Mr. Samadar Singh Manager - Casting
Material Grade : FG 260 Key Date : 3-Oct-15 Mr. Dhananjay Rai Manager - M/C Shop

Current Process Controls Action Results

Process Cause(s) / Mechanism(s) of Recommended Responsibility
Process Function / Requirements Failure Mode Effect(s) of Failure B. No. S C O D RPN
Failure Actions & Target Datre
Prevention Detection Actions Taken S O D RPN

120
Microstructure Test Not OK Casting Rejection 8 Improper Composition 3 Inprocess Inspection Sampling Test 5

80
Low Hardness Casting Rejection 8 Improper Composition 2 Inprocess Inspection Sampling Test 5

Hardness Test
80
Lab Testing High Hardness Casting Rejection 8 Improper Composition 2 Inprocess Inspection Sampling Test 5

112
High Strength Casting Rejection 7 Improper Composition 4 Inprocess Inspection Sampling Test 4

Tensile Strength
112
Low Strength Casting Rejection 7 Improper Composition 4 Inprocess Inspection Sampling Test 4

112
Work Instruction,
Excessive High DFT 7 High Pressure, Improper Ratio 4 Inprocess Inspection 4
Checklist
Painting
Grinding
Process 112
Work Instruction,
Poor Less DFt 7 Less Pressure, Improper Ratio 4 Inprocess Inspection 4
Checklist

4 of 7
 Hindustan Malleable Casting Works POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)
EICHER TRACTORS (A Unit of Tafe Motors and
Part Name FLY WHEEL CASING Customer PFMEA No. HMCW/TMTL-01 Rev. No. 0
Tractors Limited)
Part No. 9701 063 1 Key Dates Date 22/05/08 Date 22/05/08

Core Team Vishnu Agarwal, Ankur Agarwal, Jagat Singh

RES. &
S. COMPONENT POTENTIAL FAILURE RECOM. ACTION

RPN

RPN
S C FAILURE EFFECTS FAILURE CAUSES O FAILURE PREVENTION FAILURE DETECTION D TARGET S O D
No. OR PROCESS FUNCTION MODES ACTION TAKEN
DATE

Visual Inspection of
Heat Codes Missing 6 Casting Rework & Punching Operator Negligence 4 Sampling Inspection 4 96
Patterns

Mould Mould Improper Sand Preparation

3 Low 6 Extra Material 4 Inprocess Inspection Sampling Inspection 4 96
Making Hardness & Ramming

Broken Pattern, Improper Inspection of Patterns,

Broken
Appearance 6 Defective Casting Box Setting, Improper 4 Proper Setting of Box & Sampling Inspection 4 96
Cavity
Ramming Proper Ramming

High 7 Lost in Properties Improper Charge Mixing 3 CE Test Sampling Test 4 84

CE

Low 7 Lost in Properties Improper Charge Mixing 3 CE Test Sampling Test 4 84

High 7 Lost in Properties Operator's Negligence 4 100 % Monitoring Sampling Test 4 112
Pouring
Temperature
Low 7 Lost in Properties Operator's Negligence 4 100 % Monitoring Sampling Test 4 112

Melting & Microstructu

4 Not OK 7 Casting Rejection Improper Composition 4 Inprocess Inspection Sampling Test 4 112
Pouring re Test

Low
7 Casting Rejection Improper Composition 4 Inprocess Inspection Sampling Test 4 112
Hardness
Hardness
Test
High
7 Casting Rejection Improper Composition 4 Inprocess Inspection Sampling Test 4 112
Hardness

High
7 Casting Rejection Improper Composition 4 Inprocess Inspection 4508325 4 ###
Strength
Tensile
Strength
4508404 7 4507524 4508365 4 Inprocess Inspection 4508325 4 ###

O = Failure occurrence probability D = Failure detection probability Risk Priority Number RPN = S x O x D
To be filled if RPN>150 5 of 7
 Hindustan Malleable Casting Works POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)
EICHER TRACTORS (A Unit of Tafe Motors and
Part Name FLY WHEEL CASING Customer PFMEA No. HMCW/TMTL-01 Rev. No. 0
Tractors Limited)
Part No. 9701 063 1 Key Dates Date 22/05/08 Date 22/05/08

Core Team Vishnu Agarwal, Ankur Agarwal, Jagat Singh

RES. &
S. COMPONENT POTENTIAL FAILURE RECOM. ACTION

RPN

RPN
S C FAILURE EFFECTS FAILURE CAUSES O FAILURE PREVENTION FAILURE DETECTION D TARGET S O D
No. OR PROCESS FUNCTION MODES ACTION TAKEN
DATE
To be filled if RPN>150
I = Date of Implementation C = Classification S = Severity

6 of 7
 Hindustan Malleable Casting Works POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)
EICHER TRACTORS (A Unit of Tafe Motors and
Part Name FLY WHEEL CASING Customer PFMEA No. HMCW/TMTL-01 Rev. No. 0
Tractors Limited)
Part No. 9701 063 1 Key Dates Date 22/05/08 Date 22/05/08

Core Team Vishnu Agarwal, Ankur Agarwal, Jagat Singh

RES. &
S. COMPONENT POTENTIAL FAILURE RECOM. ACTION

RPN

RPN
S C FAILURE EFFECTS FAILURE CAUSES O FAILURE PREVENTION FAILURE DETECTION D TARGET S O D
No. OR PROCESS FUNCTION MODES ACTION TAKEN
DATE

Excessive 7 Pitting over Surface More Blasting Time 4 Inprocess Inspection Visual Inspection 4 112

5 Shot Blasting Blasting

Poor 7 Loose Sand Less Blasting Time 4 Inprocess Inspection Visual Inspection 4 112

More Grinding Force, More

Excessive 7 Shape Lost Grinding Cut, Unskilled 4 Inprocess Inspection Visual Inspection 4 112
Operator
Grinding
6 Grinding
Process Old / Broken Grinding
Wheel, Less Grinding Force,
Poor 7 Excessive Material Remained 4 Inprocess Inspection Visual Inspection 4 112
Less Grinding Cut, Unskilled
Operator

Cost Increases, Poor

Excessive 5 Improper Processing 4 Inprocess Inspection Visual Inspection 4 80
Adhesiveness of Paint
7 Painting Grinding

Poor 5 Increases Rework Improper Processing 5 Inprocess Inspection Visual Inspection 4 100

Dim. Oversize /
7 Increase Rework Improper Processing 3 Inprocess Inspection Sampling PDI 4 84
Inspection Undersize
Final
8
Inspection
Visual Casting
7 Casting Rejection Improper Processing 3 Inprocess Inspection Sampling PDI 4 84
Inspection Defects

O = Failure occurrence probability D = Failure detection probability Risk Priority Number RPN = S x O x D
To be filled if RPN>150
I = Date of Implementation C = Classification S = Severity

7 of 7