Doc. No.

PDC-EPD-F03

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

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

PFMEA Number D10414420A-FMEA-MCD-01 Key Contact / Phone Name / Works / Dept Team Member Department
Rev. No. (Date) 00(03/10/2015) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) 10/3/2015 Mr. Himanshu Duniwal PC
Part Number D10414410A Mr. R S Shekhawat Manager - EPD
Process Responsibility: Core Team
Part Name / Description Flywheel EURO 4550 DC Mr. Dhannjay Rai Manager - M/C Shop
Material Grade FG 260 Key Date : 3-Oct-15 Mr. Dharm Singh Manager - CMM

Current Process Controls Recom Respo Action Results

mende nsibilit
Process Function / Potential Failure
Potential Effect(s) of Failure B. No S C Potential Cause(s) / Mechanism(s) of Failure O D RPN d y&
Requirements Mode
Action Target
Prevention Detection s Date Actions Taken S O D RPN

Angle Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval,Operator Sampling Test
More / Less 1 8 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 4 64
90 ° ± 15' Assembly Problems
, Tool Wear
Monitoring,In-Process Inspection Every lot

Set up Approval /
Incorrect Programing,Incorrect Set up of
Dimension Rejection Increases, CMM Report Sampling Test
More / Less 2 8 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 4 64
67.0 Assembly Problems & Every lot
, Tool Wear
Program Controlled

Set up Approval /
Incorrect Programing,Incorrect Set up of
Dimension Rejection Increases, CMM Report Sampling Test
More / Less 3 8 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 4 64
84.9 Assembly Problems & Every lot
, Tool Wear
Program Controlled

Set up Approval /
Incorrect Programing,Incorrect Set up of
Angle Rejection Increases, CMM Report Sampling Test
35 ° ± 30'
More / Less
Assembly Problems
4 8 ▼ Fixture,loose Mounting/Clamping,Faulty Tool 2
& Every lot
4 64
Travel , Tool Wear
Program Controlled

Angle Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval,Operator Sampling Test
More / Less 5 8 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 3 48
55 ° Assembly Problems
, Tool Wear
Monitoring,In-Process Inspection Every lot

Set up Approval /
Incorrect Programing,Incorrect Set up of
Radius Rejection Increases, CMM Report Sampling Test
R135.2 / 135.5
More / Less
Assembly Problems
6 4 ▼ Fixture,loose Mounting/Clamping,Faulty Tool 2
& Every lot
4 32
Travel , Tool Wear
Program Controlled

Set up Approval /
Radius Incorrect Programing,Incorrect Set up of
Rejection Increases, CMM Report Sampling Test
R148.0 ± 0.2
More / Less
Assembly Problems
7 4 ▼ Fixture,loose Mounting/Clamping,Faulty Tool 2
& Every lot
4 32
Travel , Tool Wear
Program Controlled

Set up Approval /
Incorrect Programing,Incorrect Set up of
Dimension Rejection Increases, CMM Report Sampling Test
More / Less 8 8 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 4 64
121.2 Assembly Problems & Every lot
, Tool Wear
Program Controlled

Set up Approval /
Incorrect Programing,Incorrect Set up of
Dimension Rejection Increases, CMM Report Sampling Test
More / Less 9 8 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 4 64
131.9 Assembly Problems & Every lot
, Tool Wear
Program Controlled

Angle Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval,Operator Sampling Test
More / Less 10 8 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 3 48
65 ° Assembly Problems
, Tool Wear
Monitoring,In-Process Inspection Every lot

1 of 13
 Doc. No. PDC-EPD-F03

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

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

PFMEA Number D10414420A-FMEA-MCD-01 Key Contact / Phone Name / Works / Dept Team Member Department
Rev. No. (Date) 00(03/10/2015) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) 10/3/2015 Mr. Himanshu Duniwal PC
Part Number D10414410A Mr. R S Shekhawat Manager - EPD
Process Responsibility: Core Team
Part Name / Description Flywheel EURO 4550 DC Mr. Dhannjay Rai Manager - M/C Shop
Material Grade FG 260 Key Date : 3-Oct-15 Mr. Dharm Singh Manager - CMM

Current Process Controls Recom Respo Action Results

mende nsibilit
Process Function / Potential Failure
Potential Effect(s) of Failure B. No S C Potential Cause(s) / Mechanism(s) of Failure O D RPN d y&
Requirements Mode
Action Target
Prevention Detection s Date Actions Taken S O D RPN

Angle Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval,Operator Sampling Test
More / Less 11 8 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 3 48
60 ° Assembly Problems
, Tool Wear
Monitoring,In-Process Inspection Every lot

Angle Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval,Operator Sampling Test
More / Less 12 8 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 3 48
60 ° Assembly Problems
, Tool Wear
Monitoring,In-Process Inspection Every lot

Incorrect Programing,Incorrect Set up of

Punch Sampling Test
Not Punched Rework Increases 12C 3 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 Program Controlled 5 30
DEG_8 PS DC Every lot
, Tool Wear

Angle Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval,Operator Sampling Test
More / Less 13 8 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 4 64
60 ° Assembly Problems
, Tool Wear
Monitoring,In-Process Inspection Every lot

Incorrect Programing,Incorrect Set up of

Center Distance Rejection Increases, Set up Approval,Operator Sampling Test
More / Less 14 8 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 4 64
48.26 Assembly Problems Monitoring,In-Process Inspection Every lot
, Tool Wear

Angle Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval,Operator Sampling Test
More / Less 15 8 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 4 64
60 ° Assembly Problems
, Tool Wear
Monitoring,In-Process Inspection Every lot

Incorrect Programing,Incorrect Set up of

Punch Sampling Test
Not Punched Rework Increases 17 3 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 Program Controlled 5 30
8° , Tool Wear
Every lot

Rejection Increases,
Loose 6 2 2 24
Assembly Problems Incorrect Programing,Incorrect Set up of
12 Holes Set up Approval,Operator Sampling Test
M8X1.25 ▼ Fixture,loose Mounting/Clamping,Faulty Tool
Monitoring,In-Process Inspection Every lot
Rework Increases, Travel , Tool Wear
Tight 5 2 2 20
Assembly Problems

2
Incorrect Programing,Incorrect Set up of
PCD Rejection Increases, Set up Approval,Operator Sampling Test
ɸ 312.0± 0.1
More/Less
Assembly Problems
18 8 ▼ Fixture,loose Mounting/Clamping,Faulty Tool
Monitoring,In-Process Inspection Every lot
2 32
Travel , Tool Wear
2

Incorrect Programing,Incorrect Set up of

True Position Rejection Increases, Set up Approval &CMM Report Sampling Test
More 8 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 2 32
0.2 Assembly Problems Program Controlled Every lot
, Tool Wear

2 of 13
 Doc. No. PDC-EPD-F03

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

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

PFMEA Number D10414420A-FMEA-MCD-01 Key Contact / Phone Name / Works / Dept Team Member Department
Rev. No. (Date) 00(03/10/2015) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) 10/3/2015 Mr. Himanshu Duniwal PC
Part Number D10414410A Mr. R S Shekhawat Manager - EPD
Process Responsibility: Core Team
Part Name / Description Flywheel EURO 4550 DC Mr. Dhannjay Rai Manager - M/C Shop
Material Grade FG 260 Key Date : 3-Oct-15 Mr. Dharm Singh Manager - CMM

Current Process Controls Recom Respo Action Results

mende nsibilit
Process Function / Potential Failure
Potential Effect(s) of Failure B. No S C Potential Cause(s) / Mechanism(s) of Failure O D RPN d y&
Requirements Mode
Action Target
Prevention Detection s Date Actions Taken S O D RPN

Rejection Increases,
More 6 2 7 84
Assembly Problems Incorrect Programing,Incorrect Set up of
6 Holes Set up Approval,Operator Sampling Test
Fixture,loose Mounting/Clamping,Faulty Tool Travel
ɸ 12.8 / 13.2 Monitoring,In-Process Inspection Every lot
Rework Increases, , Tool Wear
Less 5 2 7 70
Assembly Problems

Incorrect Programing,Incorrect Set up of

PCD Rejection Increases, Set up Approval,Operator Sampling Test
ɸ 72.0± 0.2
More/Less
Assembly Problems
19 8 ▼ Fixture,loose Mounting/Clamping,Faulty Tool 2
Monitoring,In-Process Inspection Every lot
2 32
Travel , Tool Wear

Set up Approval /
Incorrect Programing,Incorrect Set up of
True Position Rejection Increases, CMM Report Sampling Test
More 8 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 2 32
0.4 Assembly Problems & Every lot
, Tool Wear
Program Controlled

Rejection Increases,
More 6 2 7 84
Assembly Problems Incorrect Programing,Incorrect Set up of
2 Holes Set up Approval,Operator Sampling Test
Fixture,loose Mounting/Clamping,Faulty Tool Travel
ɸ 6.0 Monitoring,In-Process Inspection Every lot
Rework Increases, , Tool Wear
Less 5 2 7 70
Assembly Problems

Rejection Increases,
More
Assembly Problems Incorrect Programing,Incorrect Set up of
Drill Depth Set up Approval,In-Process Sampling Test
20 6 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 5 60
25.0 mm Inspection Every lot
Rework Increases, , Tool Wear
Less
Assembly Problems

Rejection Increases,
More 5 2 7
Assembly Problems Incorrect Programing,Incorrect Set up of
Chamfer Set up Approval & Sampling Test
Fixture,loose Mounting/Clamping,Faulty Tool Travel 70
1.5X45° Program Controlled Every lot
Rework Increases, , Tool Wear
Less 4 2 7
Assembly Problems

Incorrect Programing,Incorrect Set up of

Drill Dia Sampling Test
More Rejection Increases 4 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 Set up Approval 4 32
ɸ10.00 Max Every lot
, Tool Wear

Incorrect Programing,Incorrect Set up of

Drill Depth Sampling Test
More Rejection Increases 22 4 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 Set up Approval 4 32
15.00 Max. Every lot
, Tool Wear

Incorrect Programing,Incorrect Set up of

Center Distance Sampling Test
Less Rejection Increases 4 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 Set up Approval 4 32
30.00 mm Apart Every lot
, Tool Wear

Rejection Increases,
More 5 2 7
Assembly Problems Incorrect Programing,Incorrect Set up of
Chamfer Set up Approval & Sampling Test
23 Fixture,loose Mounting/Clamping,Faulty Tool Travel
3.0X45° Program Controlled Every lot
Rework Increases, , Tool Wear
Less 4 2 7
Assembly Problems

Rework Increases,
Less 6 Incorrect Programing,Incorrect Set up of 2 7 84
Chamfer Assembly Problems Set up Approval , Sampling Test
24 Fixture,loose Mounting/Clamping,Faulty Tool Travel
1.0 X 45° Rejection Increases, Program Controlled Every lot
More 5 , Tool Wear 2 7 70
Assembly Problems

3 of 13
 Doc. No. PDC-EPD-F03

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

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

PFMEA Number D10414420A-FMEA-MCD-01 Key Contact / Phone Name / Works / Dept Team Member Department
Rev. No. (Date) 00(03/10/2015) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) 10/3/2015 Mr. Himanshu Duniwal PC
Part Number D10414410A Mr. R S Shekhawat Manager - EPD
Process Responsibility: Core Team
Part Name / Description Flywheel EURO 4550 DC Mr. Dhannjay Rai Manager - M/C Shop
Material Grade FG 260 Key Date : 3-Oct-15 Mr. Dharm Singh Manager - CMM

Current Process Controls Recom Respo Action Results

mende nsibilit
Process Function / Potential Failure
Potential Effect(s) of Failure B. No S C Potential Cause(s) / Mechanism(s) of Failure O D RPN d y&
Requirements Mode
Action Target
Prevention Detection s Date Actions Taken S O D RPN

Incorrect Programing,Incorrect Set up of

Concentricity Rejection Increases, Set up Approval/ CMM Report Sampling Test
More 25 7 Fixture,loose Mounting/Clamping,Faulty Tool 2 7 98
0.1 w.r.t. A Assembly Problems & Process Controlled Every lot
Travel , Tool Wear

Rejection Increases,
More 5 2 7 70
Assembly Problems Incorrect Programing,Incorrect Set up of
Radius Set up Approval & Sampling Test
26 Fixture,loose Mounting/Clamping,Faulty Tool Travel
R1.0 MAX. Program Controlled Every lot
Rework Increases, , Tool Wear
Less 4 2 7 56
Assembly Problems

Rework Increases,
Less 6 Incorrect Programing,Incorrect Set up of 2 7 84
Chamfer Assembly Problems Set up Approval , Sampling Test
28 Fixture,loose Mounting/Clamping,Faulty Tool Travel
1.0 X 45° Rejection Increases, Program Controlled Every lot
More 5 , Tool Wear 2 7 70
Assembly Problems

Incorrect Programing,Incorrect Set up of

Runout Rejection Increases, Set up Approval/ CMM Report Sampling Test
More 7 Fixture,loose Mounting/Clamping,Faulty Tool 2 7 98
0.1 w.r.t. A Assembly Problems & Process Controlled Every lot
Travel , Tool Wear
29 ▼
Incorrect Programing,Incorrect Set up of
Concentricity Rejection Increases, Set up Approval/ CMM Report Sampling Test
More 7 Fixture,loose Mounting/Clamping,Faulty Tool 2 7 98
0.1 w.r.t. A Assembly Problems & Process Controlled Every lot
Travel , Tool Wear

Rejection Increases,
More 5 2 7 70
Assembly Problems Incorrect Programing,Incorrect Set up of
Radius Set up Approval & Sampling Test
30 Fixture,loose Mounting/Clamping,Faulty Tool Travel
R1.0 MAX. Program Controlled Every lot
Rework Increases, , Tool Wear
Less 4 2 7 56
Assembly Problems

Incorrect Programing,Incorrect Set up of

Surface Finish Rejection Increases, Set up Approval , Sampling Test
More 31 6 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 7 84
3.2μRa Assembly Problems Program Controlled Every lot
, Tool Wear

Rejection Increases,
Less 6 2 5 60
Assembly Problems Incorrect Programing,Incorrect Set up of
Depth Sampling Test
32 Fixture,loose Mounting/Clamping,Faulty Tool Travel Set up Approval
29.0 Every lot
Rework Increases, , Tool Wear
More 5 2 5 50
Assembly Problems

Rejection Increases,
Less 6 2 4 48
Assembly Problems Incorrect Programing,Incorrect Set up of
Depth Sampling Test
33 Fixture,loose Mounting/Clamping,Faulty Tool Travel Set up Approval
33.0 Every lot
Rework Increases, , Tool Wear
More 5 2 4 40
Assembly Problems

Rework Increases,
Less 6 Incorrect Programing,Incorrect Set up of 2 7 84
Chamfer Assembly Problems Set up Approval , Sampling Test
34 Fixture,loose Mounting/Clamping,Faulty Tool Travel
1.0 X 45° Rejection Increases, Program Controlled Every lot
More 5 , Tool Wear 2 7 70
Assembly Problems

Rejection Increases,
More 6 2 6 72
Assembly Problems Incorrect Programing,Incorrect Set up of
Inner Diameter Sampling Test
35 Fixture,loose Mounting/Clamping,Faulty Tool Travel Set up Approval
Ø 149.5 / 150.5 Every lot
, Tool Wear

4 of 13
 Doc. No. PDC-EPD-F03

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

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

PFMEA Number D10414420A-FMEA-MCD-01 Key Contact / Phone Name / Works / Dept Team Member Department
Rev. No. (Date) 00(03/10/2015) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) 10/3/2015 Mr. Himanshu Duniwal PC
Part Number D10414410A Mr. R S Shekhawat Manager - EPD
Process Responsibility: Core Team
Part Name / Description Flywheel EURO 4550 DC Mr. Dhannjay Rai Manager - M/C Shop
Material Grade FG 260 Key Date : 3-Oct-15 Mr. Dharm Singh Manager - CMM

Current Process Controls Recom Respo Action Results

mende nsibilit
Process Function / Potential Failure
Potential Effect(s) of Failure B. No S C Potential Cause(s) / Mechanism(s) of Failure O D RPN d y&
Requirements Mode
Action Target
Prevention Detection s Date Actions Taken S O D RPN
Incorrect Programing,Incorrect Set up of
Inner Diameter Sampling Test
35 Fixture,loose Mounting/Clamping,Faulty Tool Travel Set up Approval
Ø 149.5 / 150.5 Every lot
Rework Increases, , Tool Wear
Less 5 2 6 60
Assembly Problems

5 of 13
 Doc. No. PDC-EPD-F03

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

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

PFMEA Number D10414420A-FMEA-MCD-01 Key Contact / Phone Name / Works / Dept Team Member Department
Rev. No. (Date) 00(03/10/2015) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) 10/3/2015 Mr. Himanshu Duniwal PC
Part Number D10414410A Mr. R S Shekhawat Manager - EPD
Process Responsibility: Core Team
Part Name / Description Flywheel EURO 4550 DC Mr. Dhannjay Rai Manager - M/C Shop
Material Grade FG 260 Key Date : 3-Oct-15 Mr. Dharm Singh Manager - CMM

Current Process Controls Recom Respo Action Results

mende nsibilit
Process Function / Potential Failure
Potential Effect(s) of Failure B. No S C Potential Cause(s) / Mechanism(s) of Failure O D RPN d y&
Requirements Mode
Action Target
Prevention Detection s Date Actions Taken S O D RPN

Rejection Increases,
More 6 2 6 72
Assembly Problems Incorrect Programing,Incorrect Set up of
Inner Diameter Sampling Test
36 Fixture,loose Mounting/Clamping,Faulty Tool Travel Set up Approval
Ø 164.5 / 165.5 Every lot
Rework Increases, , Tool Wear
Less 5 2 6 60
Assembly Problems

Rejection Increases,
More 8 2 2 32
Assembly Problems Incorrect Programing,Incorrect Set up of Set up Approval,In Process
Inner Diameter Sampling Test
Ø 328.2 / 328.3
37 ▼ Fixture,loose Mounting/Clamping,Faulty Tool Inspection,Operator
Every lot
Rework Increases, Travel , Tool Wear Monitoring,SPC
Less 7 2 2 28
Assembly Problems

Rejection Increases,
More 6 2 6 72
Assembly Problems Incorrect Programing,Incorrect Set up of
Inner Diameter Sampling Test
38 Fixture,loose Mounting/Clamping,Faulty Tool Travel Set up Approval
Ø 344.5 / 349.5 Every lot
Rework Increases, , Tool Wear
Less 5 2 6 60
Assembly Problems

Rework Increases,
More 6 2 5 60
Assembly Problems Incorrect Programing,Incorrect Set up of
Outer Diameter Sampling Test
39 Fixture,loose Mounting/Clamping,Faulty Tool Travel Set up Approval
Ø 392.5 / 387.5 Every lot
Rejection Increases, , Tool Wear
Less 5 2 5 50
Assembly Problems

Rework Increases,
Less 6 Incorrect Programing,Incorrect Set up of 2 7 84
Chamfer Assembly Problems Set up Approval , Sampling Test
40 Fixture,loose Mounting/Clamping,Faulty Tool Travel
1.0 X 45° Rejection Increases, Program Controlled Every lot
More 5 , Tool Wear 2 7 70
Assembly Problems

Incorrect Programing,Incorrect Set up of

Perpendicularity Rejection Increases, Set up Approval/ CMM Report Sampling Test
0.05 w.r.t.'A'
More
Assembly Problems
40A 7 ▼ Fixture,loose Mounting/Clamping,Faulty Tool 2
& Process Controlled Every lot
7 98
Travel , Tool Wear

Rejection Increases,
More 5 2 7 70
Assembly Problems Incorrect Programing,Incorrect Set up of
Radius Sampling Test
41 Fixture,loose Mounting/Clamping,Faulty Tool Travel Pattern Controlled
R5.0 Every lot
Rework Increases, , Tool Wear
Less 4 2 7 56
Assembly Problems

Incorrect Programing,Incorrect Set up of

Surface Finish Rejection Increases, Set up Approval , Sampling Test
More 42 6 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 7 84
6.3μRa Assembly Problems Program Controlled Every lot
, Tool Wear

Incorrect Programing,Incorrect Set up of

Surface Finish Rejection Increases, Set up Approval , Sampling Test
More 43 6 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 7 84
3.2μRa Assembly Problems Program Controlled Every lot
, Tool Wear

Incorrect Programing,Incorrect Set up of

Surface Finish Rejection Increases, Set up Approval , Sampling Test
More 44 6 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 7 84
3.2μRa Assembly Problems Program Controlled Every lot
, Tool Wear

Punch Sampling Test

Not Punched Mixing 45 5 Operator Negligence 2 Operator monitoring 2 20
D10414410A-FG260 Every lot

6 of 13
 Doc. No. PDC-EPD-F03

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

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

PFMEA Number D10414420A-FMEA-MCD-01 Key Contact / Phone Name / Works / Dept Team Member Department
Rev. No. (Date) 00(03/10/2015) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) 10/3/2015 Mr. Himanshu Duniwal PC
Part Number D10414410A Mr. R S Shekhawat Manager - EPD
Process Responsibility: Core Team
Part Name / Description Flywheel EURO 4550 DC Mr. Dhannjay Rai Manager - M/C Shop
Material Grade FG 260 Key Date : 3-Oct-15 Mr. Dharm Singh Manager - CMM

Current Process Controls Recom Respo Action Results

mende nsibilit
Process Function / Potential Failure
Potential Effect(s) of Failure B. No S C Potential Cause(s) / Mechanism(s) of Failure O D RPN d y&
Requirements Mode
Action Target
Prevention Detection s Date Actions Taken S O D RPN
Punch Sampling Test
Not Punched Mixing 45 5 Operator Negligence 2 Operator monitoring 2 20
D10414410A-FG260 Every lot

7 of 13
 Doc. No. PDC-EPD-F03

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

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

PFMEA Number D10414420A-FMEA-MCD-01 Key Contact / Phone Name / Works / Dept Team Member Department
Rev. No. (Date) 00(03/10/2015) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) 10/3/2015 Mr. Himanshu Duniwal PC
Part Number D10414410A Mr. R S Shekhawat Manager - EPD
Process Responsibility: Core Team
Part Name / Description Flywheel EURO 4550 DC Mr. Dhannjay Rai Manager - M/C Shop
Material Grade FG 260 Key Date : 3-Oct-15 Mr. Dharm Singh Manager - CMM

Current Process Controls Recom Respo Action Results

mende nsibilit
Process Function / Potential Failure
Potential Effect(s) of Failure B. No S C Potential Cause(s) / Mechanism(s) of Failure O D RPN d y&
Requirements Mode
Action Target
Prevention Detection s Date Actions Taken S O D RPN

Rejection Increases,
Less 6 2 4 48
Assembly Problems Incorrect Programing,Incorrect Set up of
Depth Set up Approval, In Process Sampling Test
46 Fixture,loose Mounting/Clamping,Faulty Tool Travel
15.5 / 15.9 Inspection Every lot
Rework Increases, , Tool Wear
More 5 2 4 40
Assembly Problems

Incorrect Programing,Incorrect Set up of

Perpendicularity Rejection Increases, Set up Approval/ CMM Report Sampling Test
0.05 w.r.t.'A'
More
Assembly Problems
7 ▼ Fixture,loose Mounting/Clamping,Faulty Tool 2
& Process Controlled Every lot
7 98
Travel , Tool Wear

46A
Incorrect Programing,Incorrect Set up of
Flatness Rejection Increases, Set up Approval & Sampling Test
0.5
More
Assembly Problems
7 ▼ Fixture,loose Mounting/Clamping,Faulty Tool 2
Program Controlled Every lot
2 28
Travel , Tool Wear

Rejection Increases,
Less 6 2 6 72
Assembly Problems Incorrect Programing,Incorrect Set up of
Depth Sampling Test
47 Fixture,loose Mounting/Clamping,Faulty Tool Travel Set up Approval
24.5/24.9 Every lot
Rework Increases, , Tool Wear
More 5 2 6 60
Assembly Problems

Rejection Increases,
Less 6 2 6 72
Assembly Problems Incorrect Programing,Incorrect Set up of
Depth Set up Approval,In Process Sampling Test
9.0 / 9.15
48 ▼ Fixture,loose Mounting/Clamping,Faulty Tool
Inspection Every lot
Rework Increases, Travel , Tool Wear
More 5 2 6 60
Assembly Problems

Rejection Increases,
Less 6 2 6 72
Assembly Problems Incorrect Programing,Incorrect Set up of
Depth Sampling Test
49 Fixture,loose Mounting/Clamping,Faulty Tool Travel Set up Approval
37.0 Every lot
Rework Increases, , Tool Wear
More 5 2 6 60
Assembly Problems

Rejection Increases,
Less 6 2 4 48
Assembly Problems Incorrect Programing,Incorrect Set up of
Depth Sampling Test
50 Fixture,loose Mounting/Clamping,Faulty Tool Travel Set up Approval
49.5 / 50.0 Every lot
Rework Increases, , Tool Wear
More 5 2 4 40
Assembly Problems

Rejection Increases,
Less 6 2 4 48
Assembly Problems Incorrect Programing,Incorrect Set up of
Depth Sampling Test
51 Fixture,loose Mounting/Clamping,Faulty Tool Travel Set up Approval
56.0 Every lot
Rework Increases, , Tool Wear
More 5 2 4 40
Assembly Problems

Rejection Increases,
Less 6 2 4 48
Assembly Problems Incorrect Programing,Incorrect Set up of
Depth Sampling Test
52 Fixture,loose Mounting/Clamping,Faulty Tool Travel Set up Approval
98.0 Every lot
Rework Increases, , Tool Wear
More 5 2 4 40
Assembly Problems

Incorrect Programing,Incorrect Set up of

Flatness Rejection Increases, Set up Approval &
0.1
More
Assembly Problems
53 7 ▼ Fixture,loose Mounting/Clamping,Faulty Tool 2
Program Controlled
Every Piece 2 28
Travel , Tool Wear

8 of 13
 Doc. No. PDC-EPD-F03

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

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

PFMEA Number D10414420A-FMEA-MCD-01 Key Contact / Phone Name / Works / Dept Team Member Department
Rev. No. (Date) 00(03/10/2015) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) 10/3/2015 Mr. Himanshu Duniwal PC
Part Number D10414410A Mr. R S Shekhawat Manager - EPD
Process Responsibility: Core Team
Part Name / Description Flywheel EURO 4550 DC Mr. Dhannjay Rai Manager - M/C Shop
Material Grade FG 260 Key Date : 3-Oct-15 Mr. Dharm Singh Manager - CMM

Current Process Controls Recom Respo Action Results

mende nsibilit
Process Function / Potential Failure
Potential Effect(s) of Failure B. No S C Potential Cause(s) / Mechanism(s) of Failure O D RPN d y&
Requirements Mode
Action Target
Prevention Detection s Date Actions Taken S O D RPN

Rework Increases,
Less 6 Incorrect Programing,Incorrect Set up of 2 7 84
Chamfer Assembly Problems Set up Approval , Sampling Test
54 Fixture,loose Mounting/Clamping,Faulty Tool Travel
1.0 X 45° Rejection Increases, Program Controlled Every lot
More 5 , Tool Wear 2 7 70
Assembly Problems

Incorrect Programing,Incorrect Set up of

Radius Rejection Increases, Set up Approval & Sampling Test
More 55 4 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 7 56
R0.6/0.8 Assembly Problems Program Controlled Every lot
, Tool Wear

Rework Increases,
More 6 2 5 60
Assembly Problems Incorrect Programing,Incorrect Set up of
Outer Diameter Sampling Test
56 Fixture,loose Mounting/Clamping,Faulty Tool Travel Set up Approval
Ø 335.5 / 340.5 Every lot
Rejection Increases, , Tool Wear
Less 5 2 5 50
Assembly Problems

Rework Increases,
More 8 2 2 32
Assembly Problems Incorrect Programing,Incorrect Set up of Set up Approval,In Process
Outer Diameter Sampling Test
57 ▼ Fixture,loose Mounting/Clamping,Faulty Tool Inspection,Operator
Ø313.45 / 313.55 Every lot
Rejection Increases, Travel , Tool Wear Monitoring,SPC
Less 7 2 2 28
Assembly Problems

Incorrect Programing,Incorrect Set up of

Dimension Rejection Increases, Set up Approval & Sampling Test
More / Less 58 6 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 7 84
164.5 / 165.5 Assembly Problems Program Controlled Every lot
, Tool Wear

Rejection Increases,
More 8 Incorrect Programing,Incorrect Set up of 2 Set up Approval,In Process 2 32
Inner Diameter Assembly Problems Sampling Test
Ø 100.000 / 100.054
60 ▼ Fixture,loose Mounting/Clamping,Faulty Tool Inspection,Operator
Every lot
Rework Increases, Travel , Tool Wear Monitoring,SPC
Less 7 2 2 28
Assembly Problems

Rejection Increases,
More 8 Incorrect Programing,Incorrect Set up of 2 Set up Approval,In Process 2 32
Inner Diameter Assembly Problems Sampling Test
Ø 39.965 / 39.990
61 ▼ Fixture,loose Mounting/Clamping,Faulty Tool Inspection,Operator
Every lot
Rework Increases, Travel , Tool Wear Monitoring,SPC
Less 7 2 2 28
Assembly Problems

Incorrect Programing,Incorrect Set up of Set up Approval,In Process

Surface Finish Rejection Increases, Sampling Test
1.6μRa
More
Assembly Problems
62 6 ▼ Fixture,loose Mounting/Clamping,Faulty Tool 2 Inspection,
Every lot
5 60
Travel , Tool Wear Program Controlled

Incorrect Programing,Incorrect Set up of

Concentricity Rejection Increases, Set up Approval/ CMM Report Sampling Test
0.05 w.r.t. A
More
Assembly Problems
63 7 ▼ Fixture,loose Mounting/Clamping,Faulty Tool 2
& Process Controlled Every lot
7 98
Travel , Tool Wear

More Can Foul other Dimensions 6 2 7 84

Incorrect Programing,Incorrect Set up of
2 Holes Set up Approval,Operator Sampling Test
64 Fixture,loose Mounting/Clamping,Faulty Tool Travel
ɸ 8.0 Monitoring,In-Process Inspection Every lot
, Tool Wear
Less Can lack in Functioning 5 2 7 70

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 Doc. No. PDC-EPD-F03

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

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

PFMEA Number D10414420A-FMEA-MCD-01 Key Contact / Phone Name / Works / Dept Team Member Department
Rev. No. (Date) 00(03/10/2015) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) 10/3/2015 Mr. Himanshu Duniwal PC
Part Number D10414410A Mr. R S Shekhawat Manager - EPD
Process Responsibility: Core Team
Part Name / Description Flywheel EURO 4550 DC Mr. Dhannjay Rai Manager - M/C Shop
Material Grade FG 260 Key Date : 3-Oct-15 Mr. Dharm Singh Manager - CMM

Current Process Controls Recom Respo Action Results

mende nsibilit
Process Function / Potential Failure
Potential Effect(s) of Failure B. No S C Potential Cause(s) / Mechanism(s) of Failure O D RPN d y&
Requirements Mode
Action Target
Prevention Detection s Date Actions Taken S O D RPN

Angle Incorrect Programing,Incorrect Set up of

Rejection Increases, Sampling Test
More / Less 65 7 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 Pattern Controlled 4 56
45 ° Assembly Problems
, Tool Wear
Every lot

Rejection Increases,
Less 6 2 4 48
Assembly Problems Incorrect Programing,Incorrect Set up of
Tap Depth Set up Approval, Sampling Test
66 Fixture,loose Mounting/Clamping,Faulty Tool Travel
25.0 In-Process Inspection Every lot
Rework Increases, , Tool Wear
More 5 2 4 40
Assembly Problems

Rejection Increases,
Less 6 2 4 48
Assembly Problems Incorrect Programing,Incorrect Set up of
Drill Depth Set up Approval, Sampling Test
67 Fixture,loose Mounting/Clamping,Faulty Tool Travel
28.0 In-Process Inspection Every lot
Rework Increases, , Tool Wear
More 5 2 4 40
Assembly Problems

Rejection Increase, Incorrect Set up of Fixture,loose Sampling Test

Ring Fitment Loose Fit NA 8 2 Process Controlled 2 32
Assembly Problems Mounting/Clamping,Low Pressure,Less Heating Every lot

Packing Standard & Supervisor Sampling Test

Packing Quantity Per Box Less or More Supply NA 8 Operator Negligence 2 2 32
Monitoring Every lot

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 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 11 of 13
 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

12 of 13
 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

13 of 13