P - FMEA FMEA No : PFMEA/D.

P ENGG/02/300

FMEA DATE :15.01.2013

G Plast Failure Modes and Effects Analysis
REV DATE: 19.09.2013

Confidential REV NO: 5

Product Family : Rear Wiper Assembly

Distribution List : Part Name : Arm head

To: Part Number : 0198 04M 331 / 01

Mr.Lokesh (Ford) Customer : Ford

1) Task -
CC To: New component development FMEA
Aruchamy -
(Prod G Plast)
Dhakshinamoorthi
2) Result - Critical characterstics
(QA - G Plast)
Ashok B (Ford) Sl.No Potential failure Mode
RPN
1 Blow Hole (Mounting Area) 120
2 Cone Angle 18° 55' - 0° 30' 96
3 Chemical composition - Not met 96

4 Diameter 7H7 96

3) Major Actions -
Location of Plant : Sl.No Actions By / Due

Simulation has done to avoid the blow holes in the critical zones (Gate provided
Coimbatore 1.1 in the critical zone)
Completed

FRECH Hot chamber with closed loop machine used to have process control and
1.2 Machine inbulid Poka Yoke
_

Expandability Test to be implemented in the casting stage to approval the set up

1.3 and batch quality
SOP

Tightening torque test to be implemted during set up approval and shift wise for
1.4 inprocess inspection
SOP

Core pin changing frequency to be defined after producing 20K shots.

2 Tool Montioring chart need to be implemented.
SOP

Spectro anlayis done at raw material stage and also at furnace during melting in
3 various zones ( Top and Bottom)
SOP

4 100% inspection wth Air Plug guage and Control chart to be implemted SOP

Working Group :
Mr.Nagamani (Eng)
Mr.Aruchamy (Prod)
Mr.Senthil (M/c)
Mr.Kumaravadivel
(Operations)

Mr.Dhakshinamoorthi (QA) 1 Cover sheet

4) Enclosures - 17 sheets of Simulation Analysis

5 Sheets of PFMEA

List of applicable parts in this product family: None

Creation / Build Realisation Approval

Moderator Supplier

Name :Nagamani Name :Aruchamy Name : Dhakshinamoorthi Name : Senthil Name : Kumaravadivel

Dept : Engineering Dept : Production Dept : Quality Dept :M/c Dept : DGM - Operations

Date : 9/11/2013 Date 10/11/2013 Date :10/11/2013 Date :10/11/2013 Date :14/11/2013

Sign : Sign : Sign : Sign : Sign :

Work Group Contact Person Responsible for Tracking Ford

Name :Nagamani Name : Prashanth.M.R Name : Ashok B Name : Name :

Dept : Engineering Dept :Quality Dept : CP/TSC3.1-IN Dept : Dept :

Date : Date : Date : 03/12/2013 Date : Date :

Sign : Sign : Sign : Sign : Sign :