Vda Fmea

GHAZIABAD PRECISION PRODUCTS PVT LTD FR-ENG-009
Process failure Mode and Effects Analysis ( Process FMEA)
PLANNING & PREPARATION ( STEP 1)

Company Name- Subject- PFMEA ID No- PFMEA/2001-2002/01
Plant Location- PFMEA Start Date- 01.01.21 Process Responsibility- Line Incharge
Customer Name- ASHOK LEYLAND PFMEA Revision Date- 25.01.21 Confidentiality level- 04
Model Year/ Platform- 2013 Cross- Functional Team- ONT/MKG/RSM/SA/KM/US/AR/PK/SM/KS/BDM
Part Name :- Rocker Arm ( Int & Exh )
CONTINOUS
IMPROVEMENT STRUCTURE ANALYSIS (STEP2) FUNCTION ANALYSIS (STEP 3) FAILURE ANALYSIS (STEP 4)
Severity (S) of FE
2. Function of the 1. Failure Effects
History / change 3.Function of the 2. Failure Mode 3. Failure Cause
process work element & (FE) to the next
3.Process Work 1. Function of the process step &
Authorization ( As 1. Process Item 2. Process Step (FM) of the (FC) of the Work
Element process Item product heigher level
applicable ) process charecteristics Process Step Element
charecteristics element
Suppleir should be
Supplier Not
Sub Supplier approved as per DS-PUR- 7
Approved
001
Not meeting the

Chemical composition As per material standard. 7
specification
To provide
Dimensional Material can be Not meeting the
10 / Incoming acceptable i.e. As per standard 7
Parameters produce rejection or specification
Inspection of Raw Conformity to the
not meeting the Wrong material
Material specs i.e.
Rocker Arm Sub To transfer motion specifications e.g :- passed on the
Dimensinal,
assembly from input to output Dimensionaly,Hardn shop floor for
Metallurgical,
ess & Microstructure further processing. Not meeting the
Metallurgy Physical and visual As per standard 7
appereance material specification
for further operation
As per standard to prevent

Not meeting the
Standard packaging any dust, damage or 6
specification
colateral damage.
Free from dust, dirt, rust,

Not meeting the
Visual apperance pitting, black spots, dents 8
specification
and any other
RISK ANALYSIS (STEP 5) OPTIMIZATION (STEP 6)
pointer to evidence
Target Completion
Control (DC) of FC
Occurrence (O) of
Current Detection
Preventive Action
Action taken with
Severity (S) of FE
Completion Date
Detection Action
Detection (D) of
Occurrence (O)
Charecteristics
Person's Name
charecteristics
Detection (D)
Responsible
Filter Code
Filter Code
PFMEA AP
PFMEA AP
(optional)
( optional
Remarks
Special
Special
FC/FM
Status
or FM
Current Prevention
date
FC
Control (PC) of FC
Non-approved supplier Material can not be

can't supply as there is procured as purchase
4 4 M - - - - - - - - - - - - - - - -
no vendor code order will not be generated
provided to them without Vendor code
Incoming Inspection, IIIrd

Chemical composition party verification,
verified for every heat. 5 procurement from 6 M - - - - - - - - - - - - - - - -
approved mills.
Inspection with Variable &

Receipt inspection 5 attribute gauges 5 M - - - - - - - - - - - - - - - -
(As per inspection format)
Inspection with variable

Metallurgical Inspection
of every lot 5 instruments (As per 5 M - - - - - - - - - - - - - - - -
inspection format)
Packaging standard
verify the packaging
defined and mentioned 7 standard material 6 M - - - - - - - - - - - - - - - -
on Purchase Order
Receipt inspection 7 Checked visually 6 M - - - - - - - - - - - - - - - -


CONTINOUS
Severity (S) of FE
History / change 3.Function of the process 2. Failure Mode
1. Function of the process step & (FE) to the next 3. Failure Cause (FC)
Authorization ( As 1. Process Item 2. Process Step 3.Process Work Element work element & process (FM) of the Process of the Work Element
process Item product heigher level
applicable ) charecteristics Step
(Cope & Drag) Dimensional Not meeting the

As per standard 7
Parameters specification
To provide
acceptable i.e. Material can be
Conformity to the As per standard to prevent produce rejection or Wrong material
20 / Pattern & Not meeting the
Rocker Arm Sub Standard packaging To transfer motion specs i.e. any dust, damage or colateral not meeting the 6 passed on the shop
Tooling specification
assembly from input to output Dimensinal, damage. specifications e.g :- floor for further
Inspection
Physical and visual Dimensionaly,Hardn processing.
appereance material ess & Microstructure
for further operation
Free from dust, dirt, rust,

Not meeting the
Visual apperance pitting, black spots, dents and 8
specification
any other
pointer to evidence
Target Completion
Control (DC) of FC
Occurrence (O) of
Current Detection
Preventive Action
Action taken with
Severity (S) of FE
Completion Date
Detection Action
Detection (D) of
Occurrence (O)
Charecteristics
Person's Name
charecteristics
Detection (D)
Responsible
Filter Code
Filter Code
PFMEA AP
PFMEA AP
(optional)
( optional
Remarks
Special
Special
FC/FM
Status
or FM
Current Prevention
date
FC
Control (PC) of FC
Inspection with Variable &

Receipt inspection 5 attribute gauges 5 M - - - - - - - - - - - - - - - -
(As per inspection format)
Packaging standard defined

verify the packaging standard
and mentioned on Purchase 7 6 M - - - - - - - - - - - - - - - -
material
Order
Receipt inspection 7 Checked visually 6 M - - - - - - - - - - - - - - - -


CONTINOUS
Severity (S) of FE
History / change 3.Function of the process
1. Function of the process step & (FE) to the next 2. Failure Mode (FM) of 3. Failure Cause (FC) of
Authorization ( As 1. Process Item 2. Process Step 3.Process Work Element work element & process
process Item product heigher level the Process Step the Work Element
applicable ) charecteristics
Depression at core due to Cavity cleaning not done on

Extra metal at
7 depletion of carbon at regular basis resulting
casting surface
corebox carbon depletion
Knowledge of M/C Operation
Skilled operator
& process parameters
Dent at casting Tool mark on corebox Cleaning done through steel

8
surface pattern rod,brush etc
Extra metal & Sand

To produce core as per Temperature variation M/C heating controller
Core Shooter M/C inclusion at 7
specification showing in M/C failure
component
Shooting of sand in Low air shooting pressure in

To proviide a constant Sand inclusion at Air pressure not maintained
Rocker Arm Sub Air Pressure To transfer motion cavity through 7 M/C resulting low strength
30 / Core Making presure to M/C for shooting casting surface constantly
assembly from input to output pressure to obtain cores
cores
Blow holes at casting Low heating temperature

To obtain hardness within
Heating Temperature not
M/C Parameters spec & good surface finish of 7
fixed at M/C
cores Extra metal & Sand
inclusion at High heating temperature
component
Lower thickness of
To obtain profile & thickness
Core Box(Cope & Drag) casting at hollow 8 Higher thickness of core pattern cavity worn out
of cores within spec
surface
Applying at pattern surface

Sand inclusion at Sand erosion from core Not properly applying spray
Silicon Spray for Proper ejection of cores 7
casting surface surface during ejection on periodicaly basis
from M/C
pointer to evidence
Target Completion
Control (DC) of FC
Occurrence (O) of
Current Detection
Preventive Action
Action taken with
Severity (S) of FE
Completion Date
Detection Action
Detection (D) of
Charecteristics
Occurrence (O)
Person's Name
charecteristics
Detection (D)
Responsible
Filter Code
Filter Code
PFMEA AP
PFMEA AP
(optional)
( optional
Remarks
Special
Special
Status
FC/FM
or FM
Current Prevention
date
FC
Control (PC) of FC
Displayed Work Monitoring in every 4 hrs &

instruction machine for 5 record in core making record 6 M - - - - - - - - - - - - - - - -
reference WI-PRD-034 DOC NO- FR-PRD-036
Displayed work Verification of pattern

instruction in machine for condition after returning &
cleaning of corebox 5 4 M - - - - - - - - - - - - - - - -
record maintain through
pattern through copper pattern history card in ERP
rod only
Preventive maintenance
Preventive maintenance Plan
done as per yearly plan
Vs actual( FR-MNT-010) &
& autonomous 5 6 M - - - - - - - - - - - - - - - -
Autonomus maintenace
maintenance on daily
checksheet (FR-MNT-004)
basis
Monitoring in every 4 hrs &

FRL installed in line to record in Set-up Approval
provide constant 3 Report 6 M - - - - - - - - - - - - - - - -
pressure to M/C ( Doc
No :- FR-PRD-036)
Monitoring in every 4 hrs & - - - - - - - - - - - - - - - -

Heating Temp fixed
record in Set-up Approval
according to process
4 Report 6 M
validation & control
( Doc
through PLC
No :- FR-PRD-036) - - - - - - - - - - - - - - - -
Shelf Life of pattern is

Monitoring through Pattern
fixed to 250000 shots &
History Card in ERP
Pattern verification is 4 6 M - - - - - - - - - - - - - - - -
(Doc No: FR-TLG-003)
done on every 50000
shots

Applying of silicon spray
in pattern after every 4
5 Report 6 M - - - - - - - - - - - - - - - -
shots to eject core
( Doc
smoothly
No :- FR-PRD-036)

CONTINOUS
Severity (S) of FE
1. Function of the process step & (FE) to the next 2. Failure Mode (FM) of the 3. Failure Cause (FC) of the
process Item product higher level Process Step Work Element
Cavity cleaning not done Cavity cleaning not done on

Depression at
8 on regular basis resulting regular basis resulting carbon
casting surface
carbon depletion depletion
Knowledge of M/C Operation
Skilled operator
& process parameters
Dent at casting Tool mark on pattern Cleaning done through steel
8
surface surface rod,brush etc
To produce Cope & Drag

Extra metal & Sand Temperature variation
Mold Making M/C mold as per specified 7 M/C heating controller failure
inclusion at casting showing in M/C
parameters
Extra metal & Sand High pattern plate

7
inclusion at casting temperature
To achieve a desired temp for
pattern in which resin coated
Pattern Plate Temp Temp thermocouple failure
sand will start bonding &
make a solid mold
Blow holes at Low pattern plate
7
casting temperature
Crack defect at
7 Low investment time
casting
Shooting of sand To achieve a desired Improper setting of investment
Investment time To transfer motion
Rocker Arm Sub in cavity through thickness of mold wrt time time in PLC
40 / Mold Making from input to
assembly gravity to obtain Blow holes at
output 7 High investment time
cope & drag molds casting
To cure the mold perfectly &

Blow holes at Improper setting of curing time
Curing time release the excess resin from 7 Low curing time
casting in PLC
mold
Low air shooting pressure

To proviide a constant Sand inclusion at Air pressure not maintained
Air Pressure 7 in M/C resulting low
presure to M/C for shooting casting surface constantly
strength cores
Blow holes at
Low heating temperature
To obtain hardness within casting
Heating Temperature not fixed
M/C Parameters spec & good surface finish of 7
Extra metal & Sand at M/C
cores
inclusion at High heating temperature
component
Lower thickness of
To obtain profile & thickness
Cope & Drag Pattern casting at hollow 8 Higher thickness of mold pattern cavity worn out
of mold within spec
surface
Applying at pattern surface

Sand inclusion at Sand erosion from core Not properly applying spray on
Silicon Spray for Proper ejection of cores 7
casting surface surface during ejection periodicaly basis
from M/C
Control (DC) of FC or
Occurrence (O) of FC
Filter Code (optional)

Filter Code ( optional
pointer to evidence
Target Completion
Current Detection
Preventive Action
Action taken with
Severity (S) of FE
Completion Date
Detection Action
Detection (D) of
Occurrence (O)
Charecteristics
Person's Name
charecteristics
Detection (D)
Responsible
PFMEA AP
PFMEA AP
Remarks
Special
Special
FC/FM
Status
Current Prevention Control
date
FM
(PC) of FC
Displayed Work instruction Monitoring in every 4 hrs &

machine for reference WI- 5 record in Mold making record 6 M - - - - - - - - - - - - - - - -
PRD-005 DOC NO- FR-PRD-0036
Displayed work instruction in Verification of pattern condition

machine for cleaning of after returning & record
5 4 M - - - - - - - - - - - - - - - -
pattern through copper rod maintain through pattern history
only card in ERP
Preventive maintenance Preventive maintenance Plan

done as per yearly plan & Vs actual( FR-MNT-010) &
5 6 M - - - - - - - - - - - - - - - -
autonomous maintenance Autonomus maintenace
on daily basis checksheet (FR-MNT-004)
1.PLC controlled 4 4 M P - - - - - - - - - - - - - - -
programming & Visual
inspection of every mold Monitoring of pattern plate temp
according to color chart once in 4hrs through IR
displayed in line pyrometer
2.Setup approval before
continous production 4 4 M P - - - - - - - - - - - - - - -
4 4 M - - - - - - - - - - - - - - - -
Process validation done & Monitoring of investment time in
fixed the spec & monitor every 4 hrs through PLC &
through PLC record in setup approval sheet
4 4 M - - - - - - - - - - - - - - - -
Process validation done & Monitoring of curing time in

fixed the spec & monitor 4 every 4 hrs through PLC & 4 M - - - - - - - - - - - - - - - -
through PLC record in setup approval sheet

FRL installed in line to record in Set-up Approval
provide constant pressure to 4 Report 6 M - - - - - - - - - - - - - - - -
M/C ( Doc No :-
FR-PRD-036)
4 Monitoring in every 4 hrs & - - - - - - - - - - - - - - -

Heating Temp fixed
according to process
validation & control through
Report 6 M P
( Doc No :-
PLC 4 - - - - - - - - - - - - - -
FR-PRD-036)
Shelf Life of pattern is fixed Monitoring through Pattern

to 250000 shots 7 pattern History Card in ERP
4 6 M - - - - - - - - - - - - - - - -
verification is done on every (Doc No: FR-TLG-003)
50000 shots

Displayed work instruction in record in Set-up Approval
machine for application of 4 Report 6 M - - - - - - - - - - - - - - - -
silicon spray in pattern ( Doc No :-
FR-PRD-036)

CONTINOUS
Severity (S) of FE
High Hardness at
8 High Si % at bath
casting
Knowledge of M/C Operation Wrong charging of raw

Skilled operator
& process parameters material in furnace
low hardness at
8 High C% at bath
casting
To melt the metal in required Slag inclusion,blow Hydrogen, nitrogen pickup Lining nature of furnace not
Induction Furnace 7
specification holes in casting in furnace during melting fixed
High & low hardness 8
To achieve the
Rocker Arm Sub To transfer motion To give the chemical result Chemical composition Internal calibration for
60 / Melting Spectrometer chemistry of part as
assembly from input to output within specific range showing out of specification spectrometer not done
per specification
Microstructural defect 8
To achieve the chemical

composition as per
High/low Hardness C% & Si% parameters not
M/C Parameters specification in order to 8 High Si & C% at bath
at casting fixed
achieve hardness & tensile
strength of component
To provide C & Si% in order High/low Hardness Failure of machine showing

CE meter 6 High Si & C% at CE meter
to match with spectrometer at casting wrong result
To achieve the desired

High/low Hardness Tapping temp not measured
Process Parameters microstructure & hardness of 8 High tapping temp
at casting by operator while tapping
component

pointer to evidence
Target Completion
Current Detection
Preventive Action
Action taken with
Severity (S) of FE
Completion Date
Detection Action
Detection (D) of
Charecteristics
Occurrence (O)
Person's Name
charecteristics
Detection (D)
Responsible
PFMEA AP
PFMEA AP
Remarks
Special
Special
Status
FC/FM
date
FM
(PC) of FC
5 6 M - - - - - - - - - - - - - - - -
Effectiveness of operator
On job training providing to
checked on every 3 months
operator regarding machine
& Skill matrix for melting
operations & effectiveness is
operation
measured in every 3 months
FR-HR-002
5 6 M - - - - - - - - - - - - - - - -
Acidic nature of lining is

fixed in furnace for increasing Monitoring of every lining
lining life & forming oxidation through furnace lining life
4 6 M - - - - - - - - - - - - - - - -
layer to form oxides which record
can remove it in the form of DOC No- FR-PRD-016
slag
3 6 M - - - - - - - - - - - - - - - -
Daily calibration of Monitoring on daily basis
spectrometer done as per through internal CRM before
internal CRM & weekly start of production & record
calibration through CRM on softcopy
3 6 M - - - - - - - - - - - - - - - -
Displayed SOP at M/C for

Monitoring on every heat
reference & without final bath
4 basis through online display 6 M - - - - - - - - - - - - - - - -
chemistry & lab approval
of spectrometer
pouring will not done
Alternate verification of Monitoring of every heat

chemistry through through spectrometer &
spectrometer for assurance 4 record on softcopy & 6 M - - - - - - - - - - - - - - - -
& Preventive maintenance Preventive maintenance Plan
done as per yearly plan Vs actual( FR-MNT-010)
Displayed SOP at M/C for Monitoring on every heat

reference & alternate basis through immersion
verification of pouring temp 5 pyrometer & record in melting 6 M P - - - - - - - - - - - - - - -
done at pouring stage to record
avoid rejection DOC NO- FR-PRD-005

CONTINOUS
Severity (S) of FE
Low & high amount of Inoculation amount of qty

8
inoculation while tapiing nt fixed
Knowledge of M/C Operation Low & High

Skilled operator
& process parameters Hardness at casting
Low & high metal tapped in Reference for tapping at

8
laddle laddle not fixed
To achieve the
desired Homogeneity / mixing of
Rocker Arm Sub To transfer motion To tap the metal in laddle in Low & High
70 / tapping Induction Furnace microstructure & 7 inoculation not done Ram sliding not working
assembly from input to output specific angle Hardness at casting
hardness of properly
component
To maintain the molten metal

Tap to pouring stage time
Laddle temp within tolerated time Cold at castings 8 Temp drop of molten metal
not fixed
range

High/low Hardness Tapping temp not measured
Process Parameters microstructure & hardness of 8 High tapping temp
at casting by operator while tapping
component

pointer to evidence
Target Completion
Current Detection
Preventive Action
Action taken with
Severity (S) of FE
Completion Date
Detection Action
Detection (D) of
Charecteristics
Occurrence (O)
Person's Name
charecteristics
Detection (D)
Responsible
PFMEA AP
PFMEA AP
Remarks
Special
Special
Status
FC/FM
date
FM
(PC) of FC
5 & Skill matrix for melting 6 M - - - - - - - - - - - - - - - -
operation
FR-HR-002
Monitoring on once per shift

Marking on laddle done for
basis & record in laddle lining
reference while tapping of 5 6 M - - - - - - - - - - - - - - - -
register DOC NO - FR-PRD-
metal
018

Vs actual
done as per yearly plan &
5 ( FR-MNT-010) & 6 M - - - - - - - - - - - - - - - -
autonomous maintenance on
daily basis
Monitoring of every heat

Displayed SOP as per
through pouring time display
process validation & fixed
5 meter & record in pouring 6 M - - - - - - - - - - - - - - - -
pouring time range to avoid
sheet
cold defect
DOC NO- FR-PRD-006
Displayed SOP at M/C for Monitoring on every heat

reference & alternate basis through immersion
verification of pouring temp 5 pyrometer & record in melting 6 M - - - - - - - - - - - - - - - -
done at pouring stage to record
avoid rejection DOC NO- FR-PRD-005

CONTINOUS
Severity (S) of FE
Cold at castings 8 Slow pouring
Knowledge of Pouring Less knowledge about

Skilled operator
method & time pouring to operator
Flash at castings 8 Fast pouring
To achieve the
desired
Rocker Arm Sub To transfer motion To run the rail system in a
80 / Pouring microstructure &
assembly Mono Rail from input to output specific time in order to Cold at castings 7 Slow pouring Pneumatic cylinder failure
hardness of
component achieve constant speed
To maintain the molten metal

Tap to pouring stage time
Laddle temp within tolerated time Cold at castings 8 Temp drop of molten metal
not fixed
range

Effect of inoculation start
Process Parameters microstructure & hardness of Microstructural defect 8 More pouring time
fading at the end of pouring
component

pointer to evidence
Target Completion
Current Detection
Preventive Action
Action taken with
Severity (S) of FE
Completion Date
Detection Action
Detection (D) of
Charecteristics
Occurrence (O)
Person's Name
charecteristics
Detection (D)
Responsible
PFMEA AP
PFMEA AP
Remarks
Special
Special
Status
FC/FM
date
FM
(PC) of FC
Displayed SOP for pouring 5 6 M - - - - - - - - - - - - - - - -

time / mold for specific part &
operation
FR-HR-002
5 6 M - - - - - - - - - - - - - - - -

Vs actual
done as per yearly plan &
5 ( FR-MNT-010) & 6 M - - - - - - - - - - - - - - - -
autonomous maintenance on
daily basis
Monitoring of every heat

Displayed SOP as per
through pouring time display
process validation & fixed
pouring time range to avoid
3 meter & record in pouring 6 M P - - - - - - - - - - - - - - -
sheet
cold defect
DOC NO- FR-PRD-006
Pouring time fixed for every Monitoring on every heat

part through process basis through pouring timer &
validation & fixed in pouring
4
record in pouring record
6 M P - - - - - - - - - - - - - - -
timer DOC NO- FR-PRD-006

CONTINOUS
Severity (S) of FE
High/Low hardness 8 Fast/Late knockout
Knowledge of knockout Less knowledge about

Skilled operator
method & time knockout to operator
Microstructural defect 8 Fast/Late knockout
To achieve the
desired
Rocker Arm Sub To transfer motion
90 / Knockout microstructure & To achieve a desired time for Timer not showing correct
assembly Knockout Timer from input to output High/Low hardness 8 Timer failure
hardness of knockout of component time
component
Variation in knoukout time

More Hardness 8 Less Knockout time
as it is not fixed
Process Parameters microstructure & hardness of
component
Increase in knockout time
Low Hardness 8 More knockout time shows decrease in
hardness of component

pointer to evidence
Target Completion
Current Detection
Preventive Action
Action taken with
Severity (S) of FE
Completion Date
Detection Action
Detection (D) of
Charecteristics
Occurrence (O)
Person's Name
charecteristics
Detection (D)
Responsible
PFMEA AP
PFMEA AP
Remarks
Special
Special
Status
FC/FM
date
FM
(PC) of FC
Displayed SOP for knockout 5 6 M P - - - - - - - - - - - - - - -

time for specific part & On
job training providing to
operation
FR-HR-002
5 6 M - - - - - - - - - - - - - - - -
Monitoring on every heat

basis & record on pouring
Alternate verification of
basis
timing through stop watch on
5 DOC NO- FR-PRD-006 6 M - - - - - - - - - - - - - - - -
per heat basis & Calibration
Calibration Plan Vs actual
done as per yearly plan
( FR-CAL-002)
5 6 M P - - - - - - - - - - - - - - -
Knockout time fixed for every Monitoring on every heat
part through process basis through knockout timer
validation & fixed in knockout & record in pouring record
timer DOC NO- FR-PRD-006
4 6 M P - - - - - - - - - - - - - - -

CONTINOUS
Severity (S) of FE
More or less ferrite/Pearlite & Not judge the defect visualy in

9
more carbide at component microstructure analysis
Knowledge of M/C operations

Fit & function failure
Skilled operator & checking Microstructure &
at customer end
hardness of component More or less hardness at Not correctly measure the
9
component reading of hardness
To check the
100 / Fitment issue in
Rocker Arm Sub microstructure &
Inspection( Metall engine assembly at
assembly hardness of
urgical) customer end
component
Chemistry showing wrong Improper flow rate of argon

9
result gas
High & low hardness 8
To give the chemical result Chemical composition Internal calibration for

Spectrometer
within specific range showing out of specification spectrometer not done
Microstructural defect 8

pointer to evidence
Target Completion
Current Detection
Preventive Action
Action taken with
Severity (S) of FE
Completion Date
Detection Action
Detection (D) of
Charecteristics
Occurrence (O)
Person's Name
charecteristics
Detection (D)
Responsible
PFMEA AP
PFMEA AP
Remarks
Special
Special
Status
FC/FM
date
FM
(PC) of FC
Trained metallurgist are only

responsible for miscrostructural
inspection & their effectiveness
checked on every 3 months &
is carried through MSA in every
4 Skill matrix for Lab 6 M - - - - - - - - - - - - - - - -
3 months
FR-HR-002
Also Grain morphology charts
are displayed in lab for
reference
On job training providing to Effectiveness of operator

operator regarding machine checked on every 3 months &
operations & effectiveness is 4 Skill matrix for Lab 6 M K - - - - - - - - - - - - - - -
measured in every 3 months FR-HR-002
through MSA
Monitoring on daily basis

Flow rate of argon gas fixed
through pressure gauge &
& displayed WI in M/C for 4 6 M - - - - - - - - - - - - - - - -
record in autonomous
reference
checksheet
4 6 M - - - - - - - - - - - - - - - -
Daily calibration of Monitoring on daily basis
spectrometer done as per through internal CRM before
internal CRM & weekly start of production & record
calibration through CRM on softcopy
4 6 M - - - - - - - - - - - - - - - -

CONTINOUS
Severity (S) of FE
Less knowledge & awareness

Knowledge of M/C operations Under dimension of
Skilled operator 7 Over grinding to operator regarding grinding
& process parameters component operations
To remove the
Rocker Arm Sub To transfer motion parting line, flashes
110 / Fettling
assembly from input to output & fins from
component suface finish not Ok rough surface of grinding Dressing not done by
7
in casting wheel operator
To grind the part as per

Bench Grinder
specification
Crack on chill face of

7 Vibration on grinding wheel Wheel alignment not done
casting

pointer to evidence
Target Completion
Current Detection
Preventive Action
Action taken with
Severity (S) of FE
Completion Date
Detection Action
Detection (D) of
Charecteristics
Occurrence (O)
Person's Name
charecteristics
Detection (D)
Responsible
PFMEA AP
PFMEA AP
Remarks
Special
Special
Status
FC/FM
date
FM
(PC) of FC
Displayed WI on shop floor for

grinding operator & On job
checked on every 3 months &
training providing to operator
5 Skill matrix for Lab 6 M - - - - - - - - - - - - - - - -
regarding machine operations &
FR-HR-002
effectiveness is measured in
every 3 months
Displayed WI for dressing Monitoring on daily basis &

procedure in M/C for 5 record in Machine 6 M - - - - - - - - - - - - - - - -
reference checksheet
Displayed WI for wheel Monitoring on daily basis &

aligning procedure in M/C for 5 record in Machine 6 M - - - - - - - - - - - - - - - -
reference checksheet

CONTINOUS
Severity (S) of FE
Counting of components
not done
Poor visual
appearance(extrametal &
Poor Surface finish on
Knowledge of M/C component at final
Skilled operator Operation & process inspection area
parameters Poor visual
To shot the
appearance(extra
To transfer motion component in
Rocker Arm Sub 120 / metal & Poor Uncleaned & surface
from input to order to achieve 6
assembly Shot Blasting Surface finish on finish not ok
output good surface
component at final
appearance
inspection area
Shots level not checked
To shot blast the

component in order to
Shot Blasting Machine Impellar work not properly
achieve good surface
appearance

pointer to evidence
Target Completion
Preventive Action
Action taken with
Severity (S) of FE
Detection Action
Completion Date
Detection (D) of
Occurrence (O)
Charecteristics
Person's Name
charecteristics
Detection (D)
Responsible
PFMEA AP
PFMEA AP
Remarks
Special
Special
FC/FM
Status
Current Prevention Control Current Detection Control (DC)
date
(PC) of FC of FC or FM
1.100% counting of
component &
Monitoring in every loading
2.Part wise loading qty
5 basis & record in shot blasting 6 M - - - - - - - - - - - - - - - -
defined in process sheet
record Doc no- FR-PRD-018
for reference Doc no- FR-
PRD-038
1.Timer is been installed in

M/C for time measurement
2.Shot blasting WI for
reference Doc no- FR-PRD-
Monitoring in every hour basis
038
4 & record in shot blasting record 6 M - - - - - - - - - - - - - - - -
3.On job training providing
Doc no- FR-PRD-018
to operator regarding
machine operations &
effectiveness is measured
in every 3 months
1.Amperage meter with

marking is installed in M/C
2.Shot blasting WI for
reference Doc no- FR-PRD-
Monitoring in every hour basis
038
5 & record in shot blasting record 6 M - - - - - - - - - - - - - - - -
3.On job training providing
Doc no- FR-PRD-003
to operator regarding
machine operations &
in every 3 months
Preventive maintenance Preventive maintenance Plan

done as per yearly plan & Vs actual( FR-MNT-010) &
5 6 M - - - - - - - - - - - - - - - -
autonomous maintenance Autonomus maintenace
on daily basis checksheet (FR-MNT-004)

CONTINOUS
Severity (S) of FE
Defective
Component 1.Less Knowledge &
Knowledge of M/C
dispatched to Surface defects missed awareness to operator
Skilled operator Operation & process 9
customer & get during visual inspection 2. Lack of visual defect
parameters
break during display
engine running
130 / Fitment issue in To check the

Rocker Arm Sub
Visual engine assembly visual defects in
assembly
Inspection at customer end component Defective
Component
To provide good lighting
dispatched to Lux level not defined at
Lighting conditon condion for observing 9 Low lux level
customer & get inspection area
defects
break during
engine running
Fit & function

To identify the OK parts & Dimension out of
Gauges failure at customer 9 Gauge worn out
reject the defect pieces specification
end

pointer to evidence
Target Completion
Preventive Action
Action taken with
Severity (S) of FE
Detection Action
Completion Date
Detection (D) of
Charecteristics
Occurrence (O)
Person's Name
charecteristics
Detection (D)
Responsible
PFMEA AP
PFMEA AP
Remarks
Special
Special
FC/FM
Status
date
Limit sample acceptance

Limit sample board are
criteria
displayed in line for
Doc No : FR-ENG-011
reference &
& Effectiveness of operator
4 checked on every 3 months 6 M - - - - - - - - - - - - - - - -
which reflects on Skill matrix of
operations & effectiveness
Final inspection
is measured in every 3
FR-HR-004
months
Lux level specified at visual

Monitoring on per shift basis &
inspection area(min 750 4 6 M - - - - - - - - - - - - - - - -
record in lux level register
lux)
Monitoring through Master list

Calibration of Gauges done
4 for calibration of gauges 6 M - - - - - - - - - - - - - - - -
according to schedule
Doc No : FR--CAL-002

CONTINOUS
Severity (S) of FE
1. Function of the process step & (FE) to the next 2. Failure Mode (FM) 3. Failure Cause (FC) of
process Item product heigher level of the Process Step the Work Element
Knowledge of M/C Fit & function

Dimension out of Less knowledge of GD&T
Skilled operator Operation & process failure at customer 9
specification to operator
parameters end
To check the
Fitment issue in
Rocker Arm Sub 140 / dimension of
engine assembly
assembly Final Inspection component as per
at customer end
customer Dwg
Fit & function

To check the component Dimension out of Uncalibrated measuring
Measuring Instruments failure at customer 9
specific dimension specification instrument used
end

pointer to evidence
Target Completion
Preventive Action
Action taken with
Severity (S) of FE
Detection Action
Completion Date
Detection (D) of
Occurrence (O)
Charecteristics
Person's Name
charecteristics
Detection (D)
Responsible
PFMEA AP
PFMEA AP
Remarks
Special
Special
FC/FM
Status
date
Monitoring of Trained personnel

Qualified & trained personel
through Standard room
are responsible for
capabilities matrix &
dimension inspection & 4 6 M - - - - - - - - - - - - - - - -
Effectiveness monitored in
every 3 months
in every 3 months
Doc No: DS-STD-001
Monitoring through Master list

Calibration of equipment
4 for calibration of gauges 6 M - - - - - - - - - - - - - - - -
done as per schedule
Doc No : FR--CAL-002

CONTINOUS
Severity (S) of FE
Rusted component
Rust prevention of To dip the component in Oiling not done on Less Knowledge &
150 / Oiling Skilled Operator dispatch to 8
final component RP as per work instruction component awareness to operator
customer
Packing of
component as per To pack the component as Customer Less Knowledge &
160 / Packing Skilled Operator 7 Improper Counting
standard/ per packing standard dissatisfaction awareness to operator
agreement
To transfer motion
Rocker Arm Sub
from input to
assembly
output
Storage of
170 / FG component as per To store the component Customer Components kept in
Storage 8 Rust in casting
Storage standard/ as per packing standard dissatisfaction floor
agreement
Dispatch of Proper documents not

To dispatch the component Customer Less Knowledge &
180 / Dispatch Skilled Operator component as per 7 attached along with
as per invoice dissatisfaction awareness to operator
invoice supply

pointer to evidence
Target Completion
Preventive Action
Action taken with
Severity (S) of FE
Detection Action
Completion Date
Detection (D) of
Charecteristics
Occurrence (O)
Person's Name
charecteristics
Detection (D)
Responsible
PFMEA AP
PFMEA AP
Remarks
Special
Special
FC/FM
Status
date
every 3 months which reflects
100% dipping application
through Skill matrix of Oiling
on component &
operation
On job training providing to 5 6 M - - - - - - - - - - - - - - - -
FR-HR-004
Work instruction for oiling
operations
operation
Doc No :- FR- ENG-023
every 3 months which reflects
Dock audit as per schedule
through Skill matrix of Packing
&
operation
On job training providing to 5 6 M - - - - - - - - - - - - - - - -
FR-HR-004
Work instruction for Packing
operations
operation
Doc No :- FR- ENG-023
Components are stored in

Monitoring through Dock audit
pallet/bins to prevent from
conduct once in every week
moisture/ rust & displayed 5 6 M - - - - - - - - - - - - - - - -
DOC NO - FR-IQA-014
WI at area for reference
DOC NO- WI-PRD-046
Monitoring in every dispatch by

Invoice control 5 6 M - - - - - - - - - - - - - - - -
store incharge

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GHAZIABAD PRECISION PRODUCTS PVT LTD FR-ENG-009

Process failure Mode and Effects Analysis ( Process FMEA)

PLANNING & PREPARATION ( STEP 1)

Not meeting the

As per standard to prevent

Free from dust, dirt, rust,

RISK ANALYSIS (STEP 5) OPTIMIZATION (STEP 6)

Action taken with

Non-approved supplier Material can not be

Incoming Inspection, IIIrd

Inspection with Variable &

Inspection with variable

Receipt inspection 7 Checked visually 6 M - - - - - - - - - - - - - - - -

Process failure Mode and Effects Analysis ( Process FMEA)

PLANNING & PREPARATION ( STEP 1)

(Cope & Drag) Dimensional Not meeting the

Free from dust, dirt, rust,

RISK ANALYSIS (STEP 5) OPTIMIZATION (STEP 6)

Action taken with

Inspection with Variable &

Packaging standard defined

Receipt inspection 7 Checked visually 6 M - - - - - - - - - - - - - - - -

Process failure Mode and Effects Analysis ( Process FMEA)

PLANNING & PREPARATION ( STEP 1)

Depression at core due to Cavity cleaning not done on

Dent at casting Tool mark on corebox Cleaning done through steel

Extra metal & Sand

Shooting of sand in Low air shooting pressure in

Blow holes at casting Low heating temperature

Applying at pattern surface

RISK ANALYSIS (STEP 5) OPTIMIZATION (STEP 6)

Action taken with

Displayed Work Monitoring in every 4 hrs &

Displayed work Verification of pattern

Monitoring in every 4 hrs &

Monitoring in every 4 hrs & - - - - - - - - - - - - - - - -

Shelf Life of pattern is

Monitoring in every 4 hrs &

Process failure Mode and Effects Analysis ( Process FMEA)

PLANNING & PREPARATION ( STEP 1)

Cavity cleaning not done Cavity cleaning not done on

To produce Cope & Drag

Extra metal & Sand High pattern plate

To cure the mold perfectly &

Low air shooting pressure

Applying at pattern surface

RISK ANALYSIS (STEP 5) OPTIMIZATION (STEP 6)

Filter Code (optional)

Action taken with

Displayed Work instruction Monitoring in every 4 hrs &

Displayed work instruction in Verification of pattern condition

Preventive maintenance Preventive maintenance Plan

Process validation done & Monitoring of curing time in

Monitoring in every 4 hrs &

4 Monitoring in every 4 hrs & - - - - - - - - - - - - - - -

Shelf Life of pattern is fixed Monitoring through Pattern

Monitoring in every 4 hrs &

Process failure Mode and Effects Analysis ( Process FMEA)

PLANNING & PREPARATION ( STEP 1)

Knowledge of M/C Operation Wrong charging of raw

High & low hardness 8

To achieve the chemical

To provide C & Si% in order High/low Hardness Failure of machine showing