NT MFG f03 Process Fmea

Doc. No. : NT-MFG-F03 RISKs Open Closed PFD NT-QA-F12 Process Flow Daigram.xlsx (sharepoint.
com)
PROCESS FAILURE MODE AND EFFECTS ANALYSIS Rev. No. (Date) 00 (03/07/2023) Open Risk - Design 0 0
Issue No. (Date) 00 (03/07/2023) Open Risk - Lab 0 0
PFMEA Number PFMEA- 01A Key Contact / Phone FMEA Stage Department Represenative Open Risk - QA 0 0
Revision No. 0 CTO Pre-launch / Pilot / Production Quality Suraj Rawat Open Risk - Process 0 0
Revision Date NA Product Sub System Electrochemistry Shreya Open Risk - SCM 0 0
Date (Originated) 9/9/2023 Linear Cell Stack Electrode Stack Assembly - Mark 4 Open High Risk 0 0
Part Number Electrode Coating Process Responsibility: Key Date : Open Medium Risk 0 0
Part Name /
All Electrdes Manufacturing - Electro Chemistry 9/9/2023
Open Low Risk 0 0
Description Total Risks 0 0
Requirements - Inputs form PFD Failure Analysis Corrrective Actions Action Results Effectivness
Recommended Actions. [ Additional Control ] What are Other Inputs
Characteristic. Current Control Methods the recommended actions for reducing the occurrence Action Results
[ One at time ] Potential Root Cause(s) / Action
Class Potential Effect(s) of Failure of the cause or improving detection?
Mechanism(s) of Failure. DETECTI Priority.
Process No. Process [ Category as [ What is the impact if this SEVERITY OCCURREN
Description per drawing, failure is not prevented or (1 - 10) What causes the step or CE (1 - 10) ON (1 - RPN [ Hightc / Responsi Target From Team Summary of
Product Process feature to go wrong? (how Prevention Detection 10) Medium / Actions bility Date. Status Sev# OCC# DET# NEW RPN Action Priority Action Evidences / Links Members Last Updated Changes
Safety,etc ] corrected? ]
could it occur? Low ]
Next Process : Fitment / Finsh Issue 6 3 Packaging done as per 5 90 Low 0

Improper packaging by Supplier. 100% Visual by
Packaging Standard.
Packaging Standard not available. Stores before
Packaging Standard
Packaging Standard not specified in unloading
Receiving of RM at No damgeed Raw specfied in PO
10 Assembly : Not possible 6 PO / Drawing. 3 Qty as per PO 5 90 Low 0
Stores. Material Trained person for
No loading and Unloading Instructions Qty as per Min.
Unloading
Strorage not proper order level
Rack available for
Customer / End user : Customer Excess Order
6 Storage 5 90 Low 0
Complaint - Performace degradation 3
Parameter Covered in
Next Process : 5 3 Supplier Inspection 5 75 Low 0
Report.
Not covered in Supplier Report / TC Supplier Inspection
IQC Report.
Not covered in IQC Report. Report available.
Training Module
Wrong Measurement Technique Inspection and
available for Inspection
Thickness out of Use of wrong / Non calibrated recording in IQC
Assembly : 5 3 Trained Inspector as 5 75 Low 0
Specification Instrument used. Report.
per skill matrix
No Deskilling for Inspection Sample Inspection
Use of Periodically
Suitable instrument not available as per Sampling
Calibrated Instruments.
Inspection sample size not adequate plan in WI
Sampling Inspection
RM Inspection of defined in Work
20A Straight and U Customer / End user : 5 3 Instruction for IQC 5 75 Low 0
Plates
Supplier Inspection
Report.
Next Process : 5 Not covered in Supplier Report / TC 3 Parameter Covered in Supplier Inspection 5 75 Low 0
Not covered in IQC Report. IQC Report. Report available.
Wrong Measurement Technique Training Module Inspection and
Dimesnions out of Use of wrong / Non calibrated available for Inspection recording in IQC
specifications Instrument used. Report.
No Deskilling for Inspection per skill matrix Sample Inspection
Suitable instrument not available Use of Periodically as per Sampling
Inspection sample size not adequate Calibrated Instruments. plan in WI
Customer / End user : 5 3 Sampling Inspection 5 75 Low 0
defined in Work
Supplier Inspection
Instruction for IQC
Report.
No SOP / WI for Measurement Training Module Inspection and
RM Inspection of available for Inspection
Chemicals - Concentration less Use of wrong / Non calibrated recording in IQC
20B Assembly : 5 3 Trained Inspector as 5 75 Low 0
Sulphuric Acid than 98 % Instrument used. Report.
[ H2So4 ] No Deskilling for Inspection per skill matrix Sample Inspection
defined in Work
Supplier Inspection
Instruction for IQC
Report.
Volumetric No SOP / WI for Measurement Training Module Inspection and
RM Inspection of Concentration less Use of wrong / Non calibrated available for Inspection recording in IQC
20C Chemical - Hydrogen Assembly : 5 3 Trained Inspector as 5 75 Low 0
than 30 % by Instrument used. Report.
Peroxide [ H2O2 ]
weight No Deskilling for Inspection per skill matrix Sample Inspection
defined in Work
Supplier Inspection
Instruction for IQC
Report.
TDS more than 10 Use of wrong / Non calibrated available for Inspection recording in IQC
PPM Instrument used. Report.
defined in Work
Supplier Inspection
Instruction for IQC
Report.
Use of wrong / Non calibrated available for Inspection recording in IQC
RM Inspection of DI
20D Not Colorless Assembly : 5 3 Trained Inspector as 5 75 Low 0
Water Instrument used. Report.
defined in Work
Supplier Inspection
Instruction for IQC
Report.
Use of wrong / Non calibrated available for Inspection recording in IQC
Not Odourless Assembly : 5 3 Trained Inspector as 5 75 Low 0
Instrument used. Report.
defined in Work
Supplier Inspection
Instruction for IQC
Report.
Use of wrong / Non calibrated recording in IQC
20E Chemical - Nickel Assembly : 5 3 Trained Inspector as 5 75 Low 0
Chloride [ NiCl2 ] per skill matrix
defined in Work
Supplier Inspection
Instruction for IQC
Report.
RM Inspection of Wrong Measurement Technique Training Module Inspection and
Chemicals - Use of wrong / Non calibrated available for Inspection recording in IQC
20F Assembly : 5 3 Trained Inspector as 5 75 Low 0
Potassium Chloride Instrument used. Report.
[ KCl ] No Deskilling for Inspection per skill matrix Sample Inspection
defined in Work
Supplier Inspection
Instruction for IQC
Report.
Use of wrong / Non calibrated recording in IQC
20G Chemical -Selenium Assembly : 5 3 Trained Inspector as 5 75 Low 0
dioxide [ SeO2 ] per skill matrix
defined in Work
Instruction for IQC
Next Process : Poor or non-uniform Under
7 3 5 105 High SOP for Solution Preparation Lab Head 11/10/2023 0
coating deposition Trained Manpower as Progress
Untrained Lab Techinician
per Skill Matrix
Parameter not defined in SOP / WI
Lab Temperature !00 % pH test by pH paper / pH
Temperature of Solution bath Under
pH Less than 2 Assembly : No Effects 5 3 Control 5 75 Low meter & recording same for every Lab Head 11/10/2023 0
Volume of Solution Progress
Calibradated pH meter batch
Improper Mixing of Solution
No Instrument to Measure
Customer / End user : Customer Reaction Plan for correction of Under
7 3 5 105 High Lab Head 11/10/2023 0
Complaint - Performace degradation bath to be made Progress
Next Process : Poor or non-uniform Under

7 3 Trained Manpower as 5 105 High SOP for Solution Preparation Lab Head 11/10/2023 0
coating deposition Progress
Untrained Lab Techinician per Skill Matrix
Parameter not defined in SOP / WI SOP for Solution
!00 % pH test by pH paper / pH
Temperature of Solution bath Preparation Under
pH More than 3 Assembly : No Effects 5 3 5 75 Low meter & recording same for every Lab Head 11/10/2023 0
Volume of Solution Lab Temperature Progress
batch
Improper Mixing in Solution Control
Customer / End user : Customer Reaction Plan for correction of Under
Solution 7 3 5 105 High Lab Head 11/10/2023 0
Complaint - Performace degradation bath to be made Progress
Preparation for
30A Anodization.
[ 10 to 15 electrode Next Process : Poor or non-uniform
in 4.2 & 7.4 Litre 7 5 5 175 High 0
coating deposition
per batch ]
Trained Manpower as
per Skill Matrix !00% time
Mixing Time Min Parameter not defined in SOP / WI
Assembly : No Effects 5 5 SOP for Solution monitoring every 5 125 Medium 0
1.5 Hrs No Instrument to Measure
Preparation batch
No Timer alarm for Mistake proofing
Customer / End user : Customer
7 5 5 175 High 0
Complaint - Performace degradation
Probablity of having raw material

Next Process : No Effect 4 5 Trained Manpower as 5 100 Medium 0
packaging as per tank size
per Skill Matrix
Improper Mixing SOP for Solution
Ratio [ 50% water Preparation Recording in weght
Assembly : No Effects 4 Parameter not defined in SOP 5 5 100 Medium 0
+ 25% H2So4 + RM Purchase as per per in Batch Report
25% H2O2 ] bath requirements
SOP for correction of
Customer / End user : Customer batch
7 5 5 175 High 0
Next Process : No Effect 4 5 5 100 Medium 0

Trained Manpower as
per Skill Matrix
Untrained Lab Techinician WI for Visual Inspection
No damage to 100% Visual
Assembly : No Effects 4 No SOP for handling 5 Creteria 5 100 Medium 0
coating Inspection
No Inspection during coating WI for handling Coated
mareial
7 5 5 175 High 0
Next Process : No Effect 4 5 5 100 Medium 0

Trained Manpower as
per Skill Matrix
Coating to be Untrained Lab Techinician WI for Visual Inspection
100% Visual
uniform Assembly : No Effects 4 No SOP for handling 5 Creteria 5 100 Medium 0
Inspection
throughout No Inspection during coating WI for handling Coated
mareial
7 5 5 175 High 0
30B Anodization of
Electrode
Next Process : 5 5 5 125 Medium 0
!00% time
Trained Manpower as monitoring and
per Skill Matrix recording for every
Time Min. 4hrs Assembly : 5 5 Parameter to be batch 5 125 Medium 0
Parameter not defined in SOP / WI
included in SOP / WI 2hrs Recording
No Timer alarm for Mistake proofing
Frequency during
process
Customer / End user : 5 5 5 125 Medium 0

!00% time
Trained Manpower as monitoring and
Untrained Lab Techinician per Skill Matrix recording for every
Current Min 0.3
Assembly : 5 No Instrument to Measure 5 Parameter to be batch 5 125 Medium 0
amp per electrode
Parameter not defined in SOP / WI included in SOP / WI 2hrs Recording
Frequency during
process
Next Process : 5 5 Trained Manpower as 5 125 Medium

per Skill Matrix
Wrong Mixing
SOP for Solution
Ratio [ 4gm NiCl2 Untrained Lab Techinician
Preparation Recording in weght
+ 0.65 gm SeO2 + Assembly : 5 Parameter not defined in SOP 5 5 125 Medium 0
RM Purchase as per per in Batch Report
49 gm KCl as Re- No Instrument to Measure
bath requirements
agent ]
SOP for correction of
Customer / End user : 5 batch 5 125 Medium 0
5
Catalyst Solution
preparation for Mixing Time Less
40A Electro-deposition [ Assembly : 5 5 5 125 Medium 0
6 electrode in 1 Ltr
than 10 Min
per batch ]
Assembly : 5 5 5 125 Medium 0
Catalyst
deposition active
area less than
30sqcm
Catalyst coating
deposition non- Assembly : 5 5 5 125 Medium 0
uniform
Dent / damage /
Scratch in coated Assembly : 5 5 5 125 Medium 0
area
Voltage min. -0.7

40B Catalyst Deposition Assembly : 5 5 5 125 Medium 0
V

Less Current [ 60
to 90 mA for
Straight & 120 to Assembly : 5 5 5 125 Medium 0
150 mA for U
Electrode ].

More Current [ 60
to 90 mA for
Straight & 120 to Assembly : 5 5 5 125 Medium 0
150 mA for U
Electrode ].
Deposition time
less than 10min
Deposition time
less than 10min
Catalyst
deposition active
area less than
30sqcm

50 Final Inspection
Dent / damage /
Scratch in coated Assembly : 5 5 5 125 Medium 0
area
Packaging of
60 Assembly : 5 5 5 125 Medium 0
Electrodes
70 Temperory Storage Assembly : 5 5 5 125 Medium 0
Transport to Cell
80 Assembly : 5 5 5 125 Medium 0
Unit for Assembly
0
Open Risk - Design 0
Doc. No. Open Risk - Mfg 0
PROCESS FAILURE MODE AND EFFECTS ANALYSIS Rev. No. (Date) Open Risk - QA 0
Issue No. (Date) Open Risk - Process 3 2
PFMEA Number PFMEA- 01.D Key Contact / Phone FMEA Stage Team Member Deparment Open Risk - Maintenance 0
Class
Process / Functional
Requirements.
Process No. & Characteristic [ Category Potential Effect(s) of Failure
SEVERITY (1 -
Potential Root Cause(s) / Mechanism(s)
of Failure. OCCURRENCE
Current Control Methods
DETECTION
Recommended Actions. [ Additional Control ]
Action Priority. What are the recommended actions for reducing the occurrence of the cause or improving detection? Action Results Open Risks 4 Closed Risks 2
Name as per [ What is the impact if this failure is not RPN [ Hightc / Action Priority
[ What are the Functions, 10) What causes the step or feature to go (1 - 10) (1 - 10)
[As per PFD] drawing, prevented or corrected? ] Medium / Low ] From UL or Summary of
Features or Requirements?} Product Process wrong? (how could it occur? Prevention Detection Actions Responsibility Target Date. Status Sev# OCC# DET# NEW RPN Action Evidences / Links Last Updated
Safety,etc ] Newtrace Changes
Next Process : Electrode transfer will
6 1 2 12 Low 0
not be proper
1. Improper packaging by Supplier.
Assembly : No effect 6 2. Packaging Standard not available. 1 2 12 Low 0
1. Packaging done as per Packaging IQC Report
Free from 3. Packaging Standard not specified in
Standard. Supplier Report
Membrane Receipt 10 Scratch, Dent, PO / Drawing.
2. Packaging Standard specfied in 100% Visual Inspection of
Bend 4. No loading and Unloading Instructions
PO packaging.
Customer / End user : Performance 5. Strorage not proper
6 6. FIFO not maintained. 1 2 12 Low 0
degradation.
Next Process : Electrode loading is

4 7 6 168 Medium
higher, cost will increase 1. 100 % Batchwise viscosity
1. Lab Temperature monitoring. value monitoring and
Assembly : No effect 1 1. Room Temperature 1 2. Periodic Viscometer Calibration recoeding in 1 1 Low 0
Anode solution 3. Periodic Calibartion of Stirrer 2. Build book [ Need to
2. Temperature of Stirrer
or cathode Temperature sensor. doument ]
CTQ 3. Weight of Catalyst
solution 4. Trained Manpower as per skill 3. MEA Check list (Visual
4. Volume of Solution
viscocity is high matrix (HR/F/02) Inspection of MEA for uneven
5. Ratio of Solution
Customer / End user : No effect. 1 1 5. SOP for Viscosity Checking coating. 1 1 Low 0
(QC/F/99, QC/F/100) (QC/F/42,QC/F/41)
Next Process : Electrode loading is Clean room for solution preparation

Regular cleaning and calibration of Process -
lesser than specification, stack 7 7 6 294 High Open 0
weighing balance and pipette should Rajalaxmi
performance will be reduced. Conductivity ETD:
1. Lab Temperature monitoring. 1. Batchwise viscosity value be followed-Cleaning procedure and 10.06.2023
2. Periodic Viscometer Calibration monitoring. auto calibration of weighing balance
1. Room Temperature have been incorporated in SOP.
Anode solution 3. Periodic Calibartion of Stirrer 2. Build book [ Need to PSD: Waiting for Engg
2. Temperature of Stirrer
or cathode Temperature sensor. doument ] device to arrive. To order
CTQ 3. Weight of Catalyst
solution Assembly : Uneven coating transfer on 4. Trained Manpower as per skill 3. MEA Check list (Visual Conductivity of DI water- Tabletop for Prod after Engg
4. Volume of Solution Process -
viscocity is low MEA leading to reduced stack 7 1 matrix (HR/F/02) Inspection of MEA for uneven 2 14 Medium conductivity and TDS Ph meters to be Qualification Open 0
5. Ratio of Solution Rajalaxmi
performance. 5. SOP for Viscosity Checking coating. purchased(ThermoFischer
(QC/F/99, QC/F/100) (QC/F/42,QC/F/41) Scientific,model-Eutech pH 700 Meter 1,2: ETD is after shifting to
With ATC Probe) new facility
Anode and cathode solution 20A and 20B Customer / End User: Customer
preparation Process -
dissatisfaction - MEA lifetime will 7 1 2 14 Medium PSD to be implemented for IPA Use Open 0
Rajalaxmi
reduced. Digital hydrometer to check quality
parameter of IPA.
Next Process : Viscocity of solution can

6 2 2 24 Low 0
be affected, leading to defects in MEA
1. Temperature is monitored
by room temperature clock
Temperature Assembly : Could lead to reduction of Probaility of failure of AC
6 2 2. Recording the room 2 24 Low 0
more than 26 stack performance Probaility of failure of dehumdifier
1. Periodic maintenence of AC (ISO) temperature data in daily
Deg C Power failure
checklist.
(QC/F/42,QC/F/41)
Customer / End User: Customer
dissatisfaction - Stack lifetime can be 6 2 2 24 Low 0
affected
Next Process : Viscocity of solution can

6 3 2 36 Low 0
be affected, leading to defects in MEA
Assembly : Could lead to reduction of Probability of failure of motor in stirrer 1. Daily RPM is recording in
Low RPM of 6 3 1. RPM is defined in the SOP 2 36 Low 0
stack performance Malfunctioning of RPM meter. the checklist.
stirrer. (QC/F/42)
Wrong setting on the RPM meter. (QC/F/42,QC/F/41)

dissatisfaction - Stack lifetime can be 6 3 2 36 Low 0
affected
Next Process : Electrode transfer will 6 7 6 252 Medium

not be proper 1. Lab Temperature monitoring.
Solution preparation is not proper which 2. Periodic Viscometer Calibration
can happen due to: 3. Periodic Calibartion of Stirrer
Assembly : Uneven coating transfer on 1. Batchwise viscosity value
Room Temperature Temperature sensor.
MEA leading to reduced stack 6 1 monitoring. 2 12 Low 0
Non- Uniform Temperature of Stirrer 4. Trained Manpower as per skill
performance. 2. Build book [ Need to
ink dispersion Weight of Catalyst matrix (HR/F/02)
doument ]
Volume of Solution 5. SOP for Viscosity Checking
Customer / End User: Customer Ratio of Solution (QC/F/99, QC/F/100)
dissatisfaction - Reduced product Sonication of ink solution 6. Periodic ultrasonicator
6 1 calibration 2 12 Low 0
performance and MEA lifetime will
reduced.
Next Process : Electrode transfer will

6 6 6 216 Medium 0
not be proper Doctor blade is not set to right speed 1. Lab Temperature monitoring.
1. Batchwise viscosity value
Solution is not proper due to following 2. Periodic Viscometer Calibration
monitoring.
Assembly : Uneven coating transfer on reasons: 3. Periodic Calibartion of Stirrer
2. Build book [ Need to
Visual defect in MEA leading to reduced stack 6 Room Temperature 1 Temperature sensor. 2 12 Low 0
doument ]
coating performance. Temperature of Stirrer 4. Trained Manpower as per skill
3. Check the doctor blade
Weight of Catalyst matrix (HR/F/02)
speed before every coating
Customer / End User: Customer Volume of Solution 5. SOP for Viscosity Checking
(QC/F/43 & QC/F/44)
dissatisfaction - MEA lifetime will 6 Ratio of Solution 1 (QC/F/99, QC/F/100) 2 12 Low 0
reduced.

4 4 6 96 Low 0
higher, cost will increase
1. Thickness to measured in
High Coating Doctor blade opening is more than 1. Doctor blade opening gap every batch using thickness
Assembly : No effect 2 1 1 2 Low 0
Thickness required specified in SOP (PR/WI/18) profiler
(PR/WI/18)
Customer / End user : No effect. 4 1 1 4 Low 0

lesser than specification, stack 6 4 6 144 Low 0
performance will be reduced.
Catalyst coating thickness

30A and 30B Assembly : Uneven coating transfer on 1. Doctor blade opening gap to be 1. Thickness to measured in
unifomity Low Coating
MEA leading to reduced stack 6 Doctor blade opening is less than required 1 measured using filler gauge every batch using thickness 2 12 Low 0
Thickness
performance. (PR/WI/18) profiler (PR/WI/18)

dissatisfaction - MEA lifetime will 6 1 2 12 Low 0
reduced.
Next Process : More catalyst will go to

4 3 6 72 Low 0
scrap, cost will increase
Length and
width of 1. Doctor blade needs to be set as 1. Length and width of coating
Assembly : No effect 2 Improper setting of Doctor blade 1 1 2 Low 0
coating is per SOP(PR/WI/18) to be measured (PR/WI/18)
higher
Customer / End user : No effect. 4 1 1 4 Low 0
Next Process : Electrode loading is not
on entire MEA, performance will be 6 3 6 108 Low 0
reduced.
Length and
Assembly : Incomplete coating on MEA 1. Doctor blade needs to be set as 1. Length and width of coating
width of 6 Improper setting of Doctor blade 1 2 12 Low 0
leading to reduced stack performance. per SOP(PR/WI/18) to be measured (PR/WI/18)
coating is lower
dissatisfaction - Stack performance is 6 1 2 12 Low 0
reduced
Next Process : Can affect the thickness
6 3 4 72 Low 6 3 4 72 Low
and uniformity of MEA
1. SOP - Doctor blade speed setting.
Speed of
Assembly : Stack performance can be (PR/WI/18) 1. Length and width of coating
doctor blade 6 Doctor blade settings not proper 1 2 12 Low Periodic Calibration of Doctor Blade. QA - Suraj R 15.2.2023 Closed 6 1 2 12 Low
affected 2. Display for Doctor Blade speed to be measured (PR/WI/18)
[ Anode
Customer / End User: Customer 3. Machine controlled Speed Seting
dissatisfaction - Stack performance is 6 1 2 12 Low 6 1 2 12 Low
reduced
Next Process :Decrease the thickness 1. Daily monitoring of Doctor
7 3 Blade opening and recording 4 84 High QA - Suraj R 6 3 4 72 Low
coating and uniformity of MEA -
Less Opening in Check list(QC/F/44,
Assembly : Stack performance can be Doctor blade settings not proper 1. SOP - Doctor blade opening QC/F/43)
of doctor 7 1 2 14 Medium Periodic Calibration of Doctor Blade. 15.2.2023 Closed 6 1 2 12 Low
affected Condition of Doctor Blade setting. 2. Daily Monitoring of Length
blade QA - Suraj R
Customer / End User: Customer and width of coating and
dissatisfaction - Stack performance is 7 1 recording in Check 2 14 Medium 6 1 2 12 Low
1. 100% Inspection
list(QC/F/44, of MEA for
QC/F/43)
reduced 1. SOP Monitoring of Time/ Active Area and recording in
Next Process : Can lead to shorting in 1. Improper setting of Time/Pressure/ pressure/ temperature while doing Check list - MEA QC Development of jig to place electrode
High Active hot press operation (QC/F/45) (QC/F/46,QC/F/45,QC/F/50) and membrane assembly in hot press
stack and hence affect stack 7 Temperatre in hot press 5 6 210 High Tooling - Ajith Patil 30.03.2023 Open 0
area dimension 2. Perodic Calibartion of Pressuge 2. 100% Inspection of MEA for to prevent misalignment (Concept
performance 2. Improper cutting of electrode
gauge and temperature sensor, Active Area and recording in development in progress)
Timer. 1. 100%
Daily Inspection
Check list of MEA for
1. SOP Monitoring of Time/ Active Area and recording in
(QC/F/46,QC/F/45,QC/F/50)
1. Improper setting of Time/Pressure/ pressure/ temperature while doing Check list - MEA QC
Low Active area Next Process : Stack performce is hot press operation (QC/F/45) (QC/F/46,QC/F/45,QC/F/50)
7 Temperatre in hot press 5 6 210 High Refer cell 53 Tooling - Ajith Patil 30.03.2023 Duplicate Action 0
dimensions reduced due to less catalyst. 2. Perodic Calibartion of Pressuge 2. 100% Inspection of MEA for
2. Improper cutting of electrode 1. 100%Area
Inspection of MEAinfor
gauge and temperature sensor, Active and recording
Timer. Membrane
Daily Check size
list as per drawing
and recording in Check list -
(QC/F/46,QC/F/45,QC/F/50)
1. SOP Monitoring of Time/
1.Improper setting of Time/Pressure/ MEA QC
pressure/ temperature while doing
Decal Process 40 High Temperatre in hot press (QC/F/46,QC/F/45,QC/F/50)
Next Process : Can lead to blocking of hot press operation (QC/F/45)
Membrane 7 2. Improper cutting of Membrane 2 2. 100% Inspection of 6 84 High Refer cell 53 Tooling - Ajith Patil 30.03.2023 Duplicate Action 0
flowfields in stack 2. Perodic Calibartion of Pressuge
dimension Membrane size as per drawing
gauge and temperature sensor,
and recording in Daily Check
Timer.
list100% Inspection of MEA for
1.
(QC/F/46,QC/F/45,QC/F/50)
Membrane size as per drawing
1. SOP Monitoring of Time/ and recording in Check list -
Next Process : Can lead leak in stack 7 2 MEA QC 6 84 High Refer cell 53 Tooling - Ajith Patil 30.03.2023 Duplicate Action 0
pressure/ temperature while doing
1. Improper setting of Time/Pressure/ (QC/F/46,QC/F/45,QC/F/50)
Low Membrane hot press operation (QC/F/45)
Temperature in Hot press 2. 100% Inspection of
dimensions 2. Perodic Calibartion of Pressuge
2. Improper cutting of Membrane Membrane size as per drawing
Assembly : Stack performance can be gauge and temperature sensor,
7 2 Timer. and recording in Daily Check 3 42 Medium Tooling 0
affected list
(QC/F/46,QC/F/45,QC/F/50)
PREPARED BY REVIEWED BY APRROVED BY

Open Risk - Design 0
Doc. No. Open Risk - Mfg 0
POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS SHEET. Rev. No. (Date) Open Risk - QA 0
Issue No. (Date) Open Risk - Process 0
PFMEA Number PFMEA- 01.A Key Contact / Phone FMEA Stage Deparment Open Risk - Maintenance 0 780
Revision No. 0 Mahesh Hukkari Pre-launch / Pilot / Production Director - QA & CI Open Risk - Tooling 0
Revision Date 26.12.2022 Product Sub System Sr. Manager - Production Open Risk - NPI 0
CORE TEAM
Date (Originated) 26.12.2022 LOTUS LHC Sr.Manager - QA & CI Open Risk - Stores 0
Part Number 10000346 Process Responsibility: Key Date : Manager - Production Open High Risk 0
Part Name / Manager - Design Mechinical Open Medium Risk 0
Stack Assembly Manufacturing 26/12/2022 Manager - Design Electrical Open Low Risk 0
Description
Recommended Actions.
[ Additional Control ]
Process / Functional
Requirements.
Process No.
Potential Failure Mode
[ Characteristic ] Class
[ Category as per
Potential Effect(s) of Failure
[ What is the impact if this SEVERITY (1
Potential Root Cause(s) / Mechanism(s) of
Failure. OCCURRENCE
Current Control Methods
DETECTIO
Action Priority. What are the recommended actions for reducing the Action Results Action
Priority.
Open Risks 0 Closed Risks 44
[ What are the
[As per PFD] drawing, failure is not prevented or - 10) What causes the step or feature to go (1 - 10) N (1 - 10) RPN [ Hightc / occurrence of the cause or improving detection? [ Hightc /
Functions, Features or Medium / Low ] Medium /
Safety,etc ] corrected? ] wrong? (how could it occur? NEW
Requirements?} Product Process Prevention Detection Actions Responsibility Target Date. Status Sev# OCC# DET#
RPN
Low ] Action Evidences / Links From UL or Newtrace Last Updated Summary of Changes
Next Process : No Impact 1 2 8 16 Low

1. Not covered in Supplier Report
Assembly : Assembly not 1. Trained Inspector 1. Sampling Inspection and
6 2. Not covered in IQC Report. 1 8 48
possible as per skill matrix recording in IQC Report, QC- Low
3. Wrong Measurement Technique
Length 2. Use of Periodically F-03 Low
4. Use of wrong / Non calibrated
(More / Less) Calibrated Instruments 2. Sampling Inspection &
Instrument used.
3. Training Module Covered Supplier Inspection
5. No Deskilling for Inspection
Customer / End User: No effect 1 2 available for Inspection Report 8 16
6. Inspection sample size not adequate Low
Next Process : No Impact 2 1. Not covered in Supplier Report 2 8 32 Low

1. Trained Inspector 1. Sampling Inspection and
2. Not covered in IQC Report.
as per skill matrix recording in IQC Report, QC-
Width Assembly : Assembly not 2. Use of Periodically F-03
6 4. Use of wrong / Non calibrated 1 8 48 Low
(More / Less) possible Calibrated Instruments 2. Sampling Inspection &
Instrument used.
available for Inspection Report
Customer / End User: No effect 1 6. Inspection sample size not adequate 2 8 16 Low
Next Process : Leeds to leakage

in bundles
7 2 8 112 High Suraj Rawat
Training Module - Gen 1 BPP Inspection from RM to15.03.2023 Closed
Final Stage.pptx (sharepoint.com) 7 1 8 56 LOW

1. Trained Inspector 1. Sampling Inspection and
Assembly : No impact 1 2 as per skill matrix recording in IQC Report, QC- 8 16
3. Wrong Measurement Technique Low
Thickness 2. Use of Periodically F-03
4. Wrong / Non calibrated Instrument
( More/Less) Calibrated Instruments 2. Sampling Inspection &
used.
available for Inspection Report
6. Inspection sample size not adequate Limit Samples to me made
Customer / End User: Leeds to
leakage in bundles.
7 2 8 112 High for Good and Bad parts Suraj Rawat 15.03.2023 Closed 7 1 8 56 LOW
once drawing is freezed
42002377-1 AMP -
10 A Next Process : Leeds to leakage 1. Not covered in Supplier Report
Anode Monopolar 6 2 8 96 Low
Raw material in bundles 2. Not covered in IQC Report. 1. Trained Inspector 1. Sampling Inspection and
plate.
3. Wrong Measurement Technique as per skill matrix recording in IQC Report, QC-
Feeler gap 4. Use of Wrong / Non calibrated 2. Use of Periodically F-03
Assembly : No impact 1 2 8 16 Low
(more/Less) Instrument for measurement. Calibrated Instruments 2. Sampling Inspection &
5. No Deskilling for Inspection 3. Training Module Covered Supplier Inspection
Customer / End User: Leeds to 6. Inspection sample size not adequate available for Inspection Report
6 2 8 96 Low
leakage in bundles.
Next Process : Leads to leakage

6 2 8 96 Low
in bundles 1. Not covered in Supplier Report 1. Trained Inspector 1. Sampling Inspection and
2. Not covered in IQC Report. as per skill matrix recording in IQC Report, QC-
Overlap 3. Wrong Measurement Technique 2. Use of Use of Use of F-03
(more/Less) 4. No Deskilling for Inspection Periodically Calibrated 2. Sampling Inspection &
5. Inspection sample size not adequate Instruments Covered Supplier Inspection
6. Limit Samples not available Report
Customer / End User: No effect 1 2 8 16 Low
Next Process : Impact 6 2 8 96 Low

1. Material Test Cerificate from
Material specified in
Manufacturer.
Material Drawing & PO Material test report for
Assembly : No effect 1 2. Not Specfied in PO / Drawing 2 8 16 Low
every lot from supplier.
3. Design Specification not available
4. No third party / NABL lab confirmation
Customer / End User: No Effect 3 2 8 48 Low
Next Process : Impact 7 2 8 112 High Suraj from

Training Module - Gen 1 BPP Inspection Rawat
RM to27.01.2023 Closed
Final Stage.pptx (sharepoint.com) Low
1. Not covered in Supplier Report 1. Sampling Inspection and
2. Not covered in IQC Report. 1. Trained Inspector recording in IQC Report, QC-
3. Untrained Inspector as per skill matrix F-03
Aesthetic 4. Inspection sample size not adequate 2. WI for acceptance of 2. Sampling Inspection &
5. Limit Samples not available Mono polar plate. Covered Supplier Inspection
6. Training Modules not available. Report
Next Process : Leads to

leakage in bundles
7 2 1. Trained Inspector 8 112 High Suraj Rawat 27.01.2023 Closed
https://Newtrace.sharepoint.com/:w:/s/safety/EWnBM-6eG31BsO_T2oooYqsB2zxlXublVpZznQ3nFKGAyw Low
1. Not covered in Supplier Report 1. Sampling Inspection and
as per skill matrix
2. Not covered in IQC Report. recording in IQC Report, QC-
2. Use of Use of Use of
Length 3. Wrong Measurement Technique F-03
Assembly : No impact 6 1 Periodically Calibrated 8 48 Low
(more/Less) 4. Wrong / Non calibrated Instrument 2. Sampling Inspection &
Instruments
used. Covered Supplier Inspection
3. Training Module
5. No Deskilling for Inspection Report
Customer / End User: No effect 1 2 available for Inspection 8 16 Low

leakage in bundles
7 2 8 112 High Suraj Rawat 27.01.2023 Closed
https://Newtrace.sharepoint.com/:w:/s/safety/EWnBM-6eG31BsO_T2oooYqsB2zxlXublVpZznQ3nFKGAyw Low
1. Not covered in Supplier Report Trained Operator 1. Sampling Inspection and
Width 3. Wrong Measurement Technique F-03
(more/Less)
Assembly : No impact 6
1 Use of Use of 2. Sampling Inspection &
8 48 Low
used. Periodically Calibrated Covered Supplier Inspection
5. No Deskilling for Inspection Instruments Report

6 2 8 96 Low
leakage in bundles 1. Not covered in Supplier Report 1. Sampling Inspection and
Trained Operator
27100001-6 2. Not covered in IQC Report. as per skill matrix recording in IQC Report, QC-
Thickness 3. Wrong Measurement Technique F-03
10 B
PTL- Porous
(more/Less)
Assembly : No effect 1
8 16 Low
Transport Layer
1. Sampling Inspection and

Next Process : Impact 6 1. Not covered in Supplier Report 2 8 96
recording in IQC Report, QC- Low
2. Not covered in IQC Report. Material specified in
F-03
3. Wrong Measurement Technique Drawing & PO
Material 2. Sampling Inspection &
Assembly : No effect 1 2 Covered Supplier Inspection 8 16 Low
used.
Report
Customer / End User: 5. No Deskilling for Inspection
5 2 3. Material test report 8 80 Low
performance degradation
Next Process : leeds tro leakage

in bundle
7 2 8 112 High Suraj Rawat 15.03.2023 Closed 7 1 8 56 LOW
1. Sampling Inspection and PROD-WI-09 Guidelines for PTL Acceptance.docx
1. Trained Inspector recording in IQC Report
3. Wrong Measurement Technique Limit Samples to me made
Aesthetic as per skill matrix 2. Sampling Inspection &
Assembly : no effect 3
used.
2 2. WI for acceptance of PTL. Covered Supplier Inspection 8 48 Low for Good and Bad parts Suraj Rawat 15.03.2023 Closed 7 1 8 56 LOW
Report once drawing is freezed
Customer / End User:

6 2 8 96 Low

2. Not covered in IQC Report. as per skill matrix recording in IQC Report
Overall length Assembly : Assembly not 3. Wrong Measurement Technique
(more/Less) possible
6
1 Use of Use of 2. Sampling Inspection & 8 48 Low
Instruments Report

6 2 8 96 Low
leakage in bundles 1. Not covered in Supplier Report Trained Operator 1. Sampling Inspection and
2. Not covered in IQC Report. as per skill matrix
Active Area recording in IQC Report
Length Assembly : No impact 1
(more/Less) used. Periodically Calibrated Covered Supplier Inspection
Instruments Report
5 1 8 40 Low

6 2 8 96 Low
Active Area recording in IQC Report
Width Assembly : No impact 1
Instruments Report
5 1 8 40 Low

Overall width Assembly : Assembly not 3. Wrong Measurement Technique
6
Instruments Report
19000001-1
10 C MEA- Membrane
Electrode Assembly Next Process : Leads to
6 2 8 96 Low
Over all recording in IQC Report
thickness Assembly : No effect 1
Instruments Report

6 2 8 96 Low
Electrode recording in IQC Report
thickness Assembly : No effect 1
Instruments Report

6 1 8 48 Low
Short Testing - recording in IQC Report
Resistance Assembly : No impact 1
Instruments Report

leakage in bundles
7 2 8 112 High Suraj Rawat 15.03.2023 Closed 7 1 8 56 Low
1. Sampling Inspection and PROD-WI-05 Shorting Test Procedure for MEA.docx
2. Not covered in IQC Report. 1. Trained Inspector
recording in IQC Report
Coating & 3. Untrained Inspector as per skill matrix Limit Samples to me made
Assembly : No impact 1 2 2. Sampling Inspection & 8 16 Low Suraj Rawat 15.03.2023 Closed 7 1 8 56 LOW
Aesthetic 4. Inspection sample size not adequate 2. WI for acceptance of
5. Limit Samples not available MEA.
Covered Supplier Inspection for Good and Bad parts
Report
6. Training Modules not available.
Customer / End User:
6 2 8 96 Low
Performance degradation

leakage in bundles
1. Not covered in Supplier Report Trained Operator PROD-WI-08 Guidlines for GDL acceptance.docx
Length 3. Wrong Measurement Technique
(more/Less)
Instruments Report

leakage in bundles
1. Not covered in Supplier Report Trained Operator PROD-WI-08 Guidlines for GDL acceptance.docx
2. Not covered in IQC Report. as per skill matrix recording in IQC Report Limit Samples to me made
width 3. Wrong Measurement Technique
Assembly : No impact 1 2 Use of Use of 2. Sampling Inspection & 8 16 Low Suraj Rawat 15.03.2023 Closed 7 1 8 56 LOW
(more/Less) 4. Wrong / Non calibrated Instrument
Periodically Calibrated Covered Supplier Inspection for Good and Bad parts
used.
Instruments Report
GDL
10 D
Gas difusion layer
6 2 8 96 Low
Thickness 3. Wrong Measurement Technique
(more/Less)
Instruments Report
Next Process : leads to leakage

in bundles
1. Not covered in Supplier Report PROD-WI-08 Guidlines for GDL acceptance.docx
recording in IQC Report Limit Samples to me made
3. Untrained Inspector as per skill matrix
Aesthetic Assembly : No effect 1 2 2. Sampling Inspection & 8 16 Low Suraj Rawat 15.03.2023 Closed 7 1 8 56 LOW
4. Inspection sample size not adequate 2. WI for acceptance of
5. Limit Samples not available GDL.
Report
Customer / End User: 6. Training Modules not available.
5 1 8 40 Low

Length Assembly : Assembly not 3. Wrong Measurement Technique
6
Instruments Report

Width Assembly : Assembly not 3. Wrong Measurement Technique
6
Instruments Report
Next Process : Leeds to leakage

6 1. Not covered in Supplier Report 2 1. Trained Inspector 8 96 Low
in bundles
3. Wrong Measurement Technique 2. Use of Use of Use of
Thickness recording in IQC Report
Assembly : No impact 3 4. Use of wrong / Non calibrated 2 Periodically Calibrated 8 48 Low
(more/Less) 2. 100 % Inspection Covered
Instrument used. Instruments
Supplier Report
5. No Deskilling for Inspection 3. Training Module
Customer / End User: Leeds to 6. Inspection sample size not adequate available for Inspection
5 1 8 40 Low
leakage in bundles.

in bundles
1. Not covered in Supplier Report Trained Operator Training Module - Gen 1 BPP Inspection from RM to Final Stage.pptx
42002378 Feeler gap 3. Wrong Measurement Technique
10E
BPP- Bi-Polar Plate (more/Less)
Instruments Report

in bundles
1. Not covered in Supplier Report Trained Operator Training Module - Gen 1 BPP Inspection from RM to Final Stage.pptx
Overlap 3. Wrong Measurement Technique
(more/Less)
Instruments Report
Next Process : Impact 6 2 1. Sampling Inspection and 8 96 Low

1. Material Test Cerificate from recording in IQC Report, QC-
Manufacturer. F-03
Drawing & PO
Material 2. Not Specfied in PO / Drawing 2. Sampling Inspection &
3. Design Specification not available Covered Supplier Inspection
4. No third party / NABL lab confirmation Report
3. Material test report
42002378
10E
BPP- Bi-Polar Plate

Manufacturer. F-03
Drawing & PO
Material Assembly : No effect 1 2. Not Specfied in PO / Drawing 2 2. Sampling Inspection & 8 16 Low
Customer / End User: 3. Material test report
5 1 8 40 Low
Next Process : Leeds to

leakage in bundles
1. Not covered in Supplier Report Training Module - Gen 1 BPP Inspection from RM to Final Stage.pptx
recording in IQC Report Limit Samples to me made
3. Untrained Inspector as per skill matrix
Aesthetic Assembly : No impact 1 2 2. Sampling Inspection & 8 16 Low Suraj Rawat 15.03.2023 Closed 7 1 8 56 LOW
4. Inspection sample size not adequate 2. WI for acceptance of Bi
5. Limit Samples not available polar plate.
Report
Customer / End User: 6. Training Modules not available.
5 2 8 80 Low

Length Assembly : Assembly not 3. Wrong Measurement Technique
6
Instruments Report

Width Assembly : Assembly not 3. Wrong Measurement Technique
6
Instruments Report

6 1. Not covered in Supplier Report 2 8 96 Low
leakage in bundles
2. Not covered in IQC Report. Trained Operator 1. Sampling Inspection and
3. Wrong Measurement Technique as per skill matrix recording in IQC Report
Thickness
(more/Less)
Assembly : No impact 1 4. Use of wrong / Non calibrated 2 Use of Use of 2. Sampling Inspection & 8 16 Low
Instrument used. Periodically Calibrated Covered Supplier Inspection

leakage in bundles
7 1. Not covered in Supplier Report 2 8 112 High Suraj Rawat 15.03.2023 Closed 7 1 8 56 Low
2. Not covered in IQC Report. Trained Operator 1. Sampling Inspection and Training Module - Gen 1 BPP Inspection from RM to Final Stage.pptx
42002379-1 3. Wrong Measurement Technique as per skill matrix recording in IQC Report
Feeler gap
10 F CMP-Cathode
(more/Less)
Monopolar Plate Instrument used. Periodically Calibrated Covered Supplier Inspection

leakage in bundles
7 1. Not covered in Supplier Report 2 8 112 High Suraj Rawat 15.03.2023 Closed 7 1 8 56 Low
2. Not covered in IQC Report. Trained Operator 1. Sampling Inspection and Training Module - Gen 1 BPP Inspection from RM to Final Stage.pptx
3. Wrong Measurement Technique as per skill matrix recording in IQC Report
Overlap
(more/Less)
Next Process : No Impact 1 2 1. Sampling Inspection and 8 16 Low

Manufacturer. F-03
Drawing & PO
Material Assembly : No effect 1 2. Not Specfied in PO / Drawing 2 2. Sampling Inspection & 8 16 Low
5 2 8 80 Low
Next Process : leads to leakagr

in bundles
7 2 1. Trained Inspector 8 112 High Suraj Rawat 15.03.2023 Closed 7 1 8 56 Low
1. Not covered in Supplier Report 1. Sampling Inspection and Training Module - Gen 1 BPP Inspection from RM to Final Stage.pptx
as per skill matrix
2. Not covered in IQC Report. recording in IQC Report, QC-
2. Use of Use of Use of Limit Samples to me made
3. Untrained Inspector F-03
Aesthetic Assembly : No impact 1 2 Periodically Calibrated 8 16 Low Suraj Rawat 15.03.2023 Closed 7 1 8 56 LOW
4. Inspection sample size not adequate
Instruments
2. Sampling Inspection & for Good and Bad parts
5. Limit Samples not available Covered Supplier Inspection
3. WI for acceptance of
6. Training Modules not available. Report
Customer / End User: No effect 1 2 CMP. 8 16 Low
Next Process : Impact 3 1. Not covered in Supplier Report 2 8 48 Low

Trained Operator 1. Sampling Inspection and
Total length F-03
(more/Less)
Assembly: Impact 3 4. Use of wrong / Non calibrated 2 Use of Use of 2. Sampling Inspection &
8 48 Low

Diameter Assembly: Assembly not F-03
6 4. Use of wrong / Non calibrated 1 Use of Use of 2. Sampling Inspection &
8 48 Low

Thread length F-03
(more/Less)
8 96 Low

Hex head 3. Wrong Measurement Technique
F-03
Thickness Assembly: Impact 6 4. Use of wrong / Non calibrated 2 Use of Use of 2. Sampling Inspection &
8 96 Low
(more/Less) Instrument used. Periodically Calibrated Covered Supplier Inspection

40000151 [ Tie - Rod Hex head Width Assembly: Assembly not F-03
10 G
] (more/Less) possible
8 48 Low

Thread Assembly: Assembly not F-03
8 48 Low
Next Process : No impact 1 2 8 16 Low

1. Not covered in Supplier Report 1. Trained Inspector 1. Sampling Inspection and
3. Untrained Inspector 2. Use of Use of Use of F-03
Aesthetic Assembly : No impact 1 2 8 16 Low
4. Inspection sample size not adequate Periodically Calibrated 2. Sampling Inspection &
5. Limit Samples not available Instruments Covered Supplier Inspection
Customer / End User: 6. Training Modules not available. Report
6 2 8 96 Low

Coating 3. Wrong Measurement Technique Use of Use of F-03
thickness Assembly: Impact 3 4. Use of wrong / Non calibrated 2 8 48 Low
(more/Less) Instrument used. Periodically Calibrated 2. Sampling Inspection &
Instruments Covered Supplier Inspection
Supplier coating report Report
Next Process : Torque will vary 6 2 1. Sampling Inspection and 8 96 Low

Manufacturer. F-03
Drawing & PO
Material Assembly : No impact 1 2. Not Specfied in PO / Drawing 2 2. Sampling Inspection & 8 16 Low
6 2 8 96 Low

Length F-03
(more/Less)
8 80 Low

Width F-03
(more/Less)
8 80 Low

Thickness F-03
(more/Less)
8 64 Low

Hole dia F-03
(more/Less)
8 48 Low
Next Process : Impact 7 1. Not covered in Supplier Report 2 8 112 High Suraj Rawat 15.03.2023 Closed 7 1 8 56 Low
Trained Operator 1. Sampling Inspection and Training Module - QC acceptance of End plates, Bezel, Gasket, tie rod.docx
Parallelism F-03
(Max)
8 32 Low
5. No Deskilling for Inspection Instruments
Customer / End User: Report
1 6. Inspection sample size not adequate 2 8 16 Low

Rectangular 3. Wrong Measurement Technique
F-03
grove length Assembly: Impact 2 4. Use of wrong / Non calibrated 2 Use of Use of 2. Sampling Inspection &
8 32 Low

F-03
groove width Assembly: Impact 2 4. Use of wrong / Non calibrated 2 Use of Use of 2. Sampling Inspection &
8 32 Low

Groove width F-03
(more/Less)
8 32 Low
66000074-2 [ Anode
10 H
extra end plate]
Groove depth F-03
(more/Less)
8 32 Low

Hex dim F-03
(more/Less)
8 32 Low

Hex dim F-03
(more/Less)
8 32 Low

Hex depth F-03
(more/Less)
8 32 Low

Xylan coating F-03
(more/Less)
8 32 Low

Coating 3. Wrong Measurement Technique
F-03
thickness Assembly: no impact 2 4. Use of wrong / Non calibrated 2 Use of Use of 2. Sampling Inspection &
8 32 Low
Next Process : Impact 3 2 1. Sampling Inspection and 8 48 Low

Manufacturer. F-03
Drawing & PO
Material Assembly: Impact 2 2. Not Specfied in PO / Drawing 2 2. Sampling Inspection & 8 32 Low
4 2 8 64 Low
Next Process : Impact 7 2 8 112 High Suraj Rawat 15.03.2023 Closed 7 1 8 56 Low
1. Not covered in Supplier Report Trained Operator 1. Sampling Inspection and Training Module - QC acceptance of End plates, Bezel, Gasket, tie rod.docx
Aesthetic 4. Inspection sample size not adequate Use of Use of 2. Sampling Inspection &
5. Limit Samples not available Periodically Calibrated Covered Supplier Inspection
6. Training Modules not available. Instruments Report
Aesthetic Assembly: No impact 2
8 32 Low
5. Limit Samples not available Periodically Calibrated Covered Supplier Inspection
Customer / End User: 6. Training Modules not available. Instruments Report
6 2 8 96 Low

Length Assembly: assembly not F-03
8 80 Low
Customer / End User: No Report
Impact

Width Assembly: assembly not F-03
8 80 Low
Impact

Thickness Assembly: assembly not F-03
8 80 Low
Impact
Next Process : Impact 7 1. Not covered in Supplier Report 2 8 112 High Suraj Rawat 15.03.2023 Closed 7 1 8 56 Low
Trained Operator 1. Sampling Inspection and Training Module - QC acceptance of End plates, Bezel, Gasket, tie rod.docx
Parallelism Assembly: assembly not F-03
(Max) possible
8 80 Low
Impact

Hole dia Assembly: assembly not F-03
8 80 Low
Impact

Bezel area depth Assembly: assembly not F-03
8 80 Low
Impact

Assembly: assembly not F-03
groove length possible
8 80 Low
Impact

Groove width Assembly: assembly not F-03
8 80 Low
Impact

Groove depth Assembly: assembly not F-03
8 80 Low
66000091-2 [Anode Instrument used. Periodically Calibrated
10 I Covered Supplier Inspection
end plate] 5. No Deskilling for Inspection Instruments
Impact

H2 O ring length Assembly: assembly not F-03
8 80 Low
Impact

O ring groove 3. Wrong Measurement Technique
width possible
8 80 Low
Impact

O ring groove 3. Wrong Measurement Technique
depth possible
8 80 Low
Impact
Next Process : Chances of

5 1. Not covered in Supplier Report 2 8 80 Low
hydrogen leak 1. Sampling Inspection and
2. Not covered in IQC Report. Trained Operator
Pressure test F-03
(Not done)
Assembly: no Impact 2 4. Use of wrong / Non calibrated 2 Use of Use of 2. Sampling Inspection &
8 32 Low
Impact

Xylan coating F-03
(more/Less)
Assembly: no Impact 2 4. Use of wrong / Non calibrated 2 Use of Use of 2. Sampling Inspection &
8 32 Low
Impact

F-03
thickness Assembly: No Impact 1 4. Use of wrong / Non calibrated 2 Use of Use of 2. Sampling Inspection &
8 16 Low
Next Process : No Impact 3 2 1. Sampling Inspection and 8 48 Low

Manufacturer. F-03
Drawing & PO
Material Assembly: No Impact 2 2. Not Specfied in PO / Drawing 2 2. Sampling Inspection & 8 32 Low
5 2 8 80 Low

Assembly : No impact 2 2. Not covered in IQC Report. 2 recording in IQC Report, QC- 8 32 Low
as per skill matrix
Customer: Customer Complaint 7 5. Limit Samples not available 2 Periodically Calibrated Covered Supplier Inspection 8 112 High Suraj Rawat 15.03.2023 Closed 7 1 8 56 Low
6. Training Modules not available. Instruments Report Training Module - QC acceptance of End plates, Bezel, Gasket, tie rod.docx
End User: Performance
6 2 8 96 Low
degradation

Assembly: Impact 2 2. Not covered in IQC Report. 2 8 32 Low
Length F-03
(more/Less)
4. Use of wrong / Non calibrated Use of Use of 2. Sampling Inspection &
Instrument used. Periodically Calibrated
Customer: No impact 1 2 Covered Supplier Inspection 8 16 Low
End User: No impact 1 2 8 16 Low

Thickness F-03
(more/Less)

Assembly: assembly not Trained Operator 1. Sampling Inspection and
5 2. Not covered in IQC Report. 2 8 80 Low
possible as per skill matrix recording in IQC Report, QC-
28000121-2 [GSKT Width F-03
10 J
H2 Plenum] (more/Less)

Assembly: No Impact 2 1. Material Test Cerificate from 2 Material specified in recording in IQC Report, QC- 8 32 Low
Manufacturer. Drawing & PO F-03
Customer: Customer Complaint 5 4. No third party / NABL lab confirmation 2 Report 8 80 Low
6 2 8 96 Low
degradation

as per skill matrix
Customer: Customer Complaint 6 5. Limit Samples not available 2 Periodically Calibrated Covered Supplier Inspection 8 96 Low

5 2 8 80 Low
degradation

Length F-03
(more/Less)
Customer: No impact 1 5. No Deskilling for Inspection 2 8 16 Low
Instruments Report

Thickness F-03
(more/Less)
Instruments Report

28000124 -2 3. Wrong Measurement Technique
Width F-03
10 K [GSKT H2 3Thrree
(more/Less)
Plenum] Instrument used. Periodically Calibrated

6 2 8 96 Low
degradation
Next Process : impact 6 2 8 96 Low

as per skill matrix

6 2 8 96 Low
degradation

Length F-03
(more/Less)

Thickness F-03
(more/Less)
28000120-2 [GSKT
10 L
H2 single Plenum]
Thickness F-03
(more/Less)
Instruments Report

28000120-2 [GSKT Width F-03
10 L
H2 single Plenum] (more/Less)
Instruments Report

6 2 8 96 Low
degradation

as per skill matrix

6 2 8 96 Low
degradation

Length F-03
(more/Less)

Width F-03
(more/Less)

28000115-2 [GSKT Thickness F-03
10 M
H2O Plenum] (more/Less)
Instruments Report

6 2 8 96 Low
degradation

as per skill matrix

6 2 8 96 Low
degradation

Length F-03
(more/Less)
Instruments Report

Overall Length F-03
(more/Less)

Width F-03
(more/Less)

in bundle
Training Module - QC acceptance of End plates, Bezel, Gasket, tie rod.docx
Height F-03
(more/Less)

Parallelism F-03
(Max)

63000125-3 [Insul Thickness F-03
10 N
BB Bezel STK] (more/Less)
Instruments Report

Wall thickness F-03
(more/Less)
Instruments Report

Parallelism F-03
(Max)
Instruments Report

Flatness F-03
(Max)
Instruments Report

5 2 8 80 Low
shorting
6 2 8 96 Low
degradation

6 2 8 96 Low
shorting

as per skill matrix

6 2 8 96 Low
degradation

Width F-03
(more/Less)

Length F-03
(more/Less)

Length F-03
(more/Less)
Next Process : leads to leak in

5 2 8 80 Low
bundles
Parallelism F-03
(Max)
Customer: Customer Complaint 4 5. No Deskilling for Inspection 2 8 64 Low
Instruments Report
3 2 8 48 Low
degradation
Next Process : leads to leak in

5 2 8 80 Low
bundles
42002577-1 [BB 3. Wrong Measurement Technique
Thickness F-03
10 O Anode and cathode
(more/Less)
side bent 5mm thk] Instrument used. Periodically Calibrated Covered Supplier Inspection
Instruments Report

42002577-1 [BB
10 O Anode and cathode
side bent 5mm thk]

Whole length F-03
(more/Less)

Flatness F-03
(Max)

6 2 8 96 Low
degradation

as per skill matrix

3 2 8 48 Low
degradation

Length F-03
(More/less)
Instruments Report

28000139-3 [GSKT Thickness F-03
10 P
Interlayer 0.34 tk] (more/Less)
Instruments Report

in bundles
as per skill matrix

6 2 8 96 Low
degradation

Length F-03
(More/less)
Instruments Report

Width F-03
(More/less)

63000246-1 [PTFE Thickness F-03
10 Q
Sheet] (more/Less)

6 2 8 96 Low
degradation

as per skill matrix

3 2 8 48 Low
degradation

Width F-03
(More/less)
Instruments Report

Length F-03
(More/less)
Instruments Report

Length F-03
(More/less)
Instruments Report

in bundles
7 2 8 112 High Suraj Rawat 15.03.2023 Closed 7 1 8 56 low
Parallelism F-03
(Max)
Instruments Report

5 2 8 80 Low
in bundles
Thickness F-03
(More/less)

42002577-1 [BB- 3. Wrong Measurement Technique
Whole length F-03
10 R Anode and Cathode
(More/less)
side bent-5.7mm tk] Instrument used. Periodically Calibrated

Whole width F-03
(More/less)

5 2 8 80 Low
in bundles
Lug Thickness F-03
(More/less)
Next Process : conductivity

6 2 8 96 Low
may changes
6 2 8 96 Low
degradation

Flatness F-03
(Max)
Instruments Report
3 2 8 48 Low
degradation

as per skill matrix

3 2 8 48 Low
degradation

Thickness F-03
(More/less)
Instruments Report

5 Not covered in Supplier Report 2 8 80 Low
in bundles
Wrong Instrument used."1. Not covered
in Supplier Report
Parallelism F-03
(Max)
Instruments Report
6. Inspection sample size not adequate"
Not covered in Supplier Report
Wrong Instrument used."1. Not covered
in Supplier Report
Parallelism F-03
(Max)
6. Inspection sample size not adequate"

5 2 8 80 Low
in bundles
Flatness F-03
(Max)

Length F-03
(More/less)
Instruments Report

Width F-03
(More/less)
Instruments Report

66000083-2
10 S
[Cathode End plate]
5 2 8 80 Low
in bundles
Depth F-03
(More/less)
Instruments Report

Xylan coating F-03
(More/less)
Instruments Report
3 2 8 48 Low
degradation

F-03
thickness 4. Use of wrong / Non calibrated Use of Use of 2. Sampling Inspection &
(More/less) Instrument used. Periodically Calibrated Covered Supplier Inspection
Instruments Report
3 2 8 48 Low
degradation

6 2 8 96 Low
degradation

in bundles
7 2 8 112 High Suraj Rawat 15.03.2023 Closed 7 1 8 56 low
as per skill matrix

3 2 8 48 Low
degradation

Diameter F-03
(More/less)

Thickness F-03
(More/less)
Instruments Report

42002433-1 [Center
10 T support shim
230mm Dia]

(More/less) 3. Design Specification not available Covered Supplier Inspection
6 2 8 96 Low
degradation

Assembly : No impact 2 2 recording in IQC Report, QC- 8 32 Low
as per skill matrix
Aesthetic Not covered in Supplier Report F-03
(More/less) Wrong Instrument used. Use of Use of 2. Sampling Inspection &
Customer: Customer Complaint 4 2 Periodically Calibrated Covered Supplier Inspection 8 64 Low
Instruments Report

3 2 8 48 Low
degradation

Length F-03
(More/less)
Instruments Report

Width F-03
(More/less)
Instruments Report

Thickness F-03
(More/less)

42002432-1 [Center
10 U support shim
342*342]

Radius F-03
(More/less)

6 2 8 96 Low
degradation

as per skill matrix

5 2 8 80 Low
degradation

Assembly: Assembly not Trained Operator 1. Sampling Inspection and
Length F-03
(More/less)
Instruments Report

Width F-03
(More/less)
Instruments Report

Thickness F-03
(More/less)
Instruments Report

Parallelism F-03
(Max)
Instruments Report

6600084-1 [Cathode
10 V
extra end plate]

Assembly : No impact 2 2. Not covered in IQC Report. 2 8 32 Low
Xylan coating F-03
(More/less)
Instruments Report
3 2 8 48 Low
degradation

F-03
thickness 4. Use of wrong / Non calibrated Use of Use of 2. Sampling Inspection &
(More/less) Instrument used. Periodically Calibrated
Customer: Customer Complaint 4 2 Covered Supplier Inspection 8 64 Low
3 2 8 48 Low
degradation

1. Material Test Cerificate from Material specified in recording in IQC Report, QC-
6 2 8 96 Low
degradation

as per skill matrix

3 2 8 48 Low
degradation

OD F-03
(More/less)
Instruments Report

ID F-03
(More/less)

Thickness F-03
(More/less)
3 2 8 48 Low
degradation

42002444-2 [Guide 3. Wrong Measurement Technique
Hole dia F-03
10 W washer for OD25 BV
(More/less)
Washer] Instrument used. Periodically Calibrated

Wall thickness F-03
(More/less)
3 2 8 48 Low
degradation

Assembly: Impact 2 1. Material Test Cerificate from 2 Material specified in recording in IQC Report, QC- 8 32 Low
6 2 8 96 Low
degradation

as per skill matrix

3 2 8 48 Low
degradation

OD F-03
(More/less)
Instruments Report

ID F-03
(More/less)
Instruments Report

Hole dia F-03
(More/less)
Instruments Report

Thickness F-03
(More/less)
Instruments Report
42002492-1 [Merged
10 X guide washer for OD End User: Performance
6 2 8 96 Low
25 BV Washers] degradation

Counter Depth F-03
(More/less)

Wall thickness F-03
(More/less)
6 2 8 96 Low
degradation
Next Process : performance

5 2 1. Sampling Inspection and 8 80 Low
degradation
1. Material Test Cerificate from Material specified in recording in IQC Report, QC-
Assembly: No Impact 2 Manufacturer. 2 F-03 8 32 Low
2. Not Specfied in PO / Drawing
Drawing & PO 2. Sampling Inspection &
Material
Customer: Customer Complaint 5 3. Design Specification not available 2 Covered Supplier Inspection 8 80 Low
End User: Performance 3. Material test report
6 2 8 96 Low
degradation

as per skill matrix

6 2 8 96 Low
degradation
Next Process : No impact 5 5 8 200 Medium 5 3 1 15 low
Assembly : Leads to leakage in MEA dimension check
8 Untrained Operator 2 from IQC 8 128 High 8 2 1 16 low
bundles Bundle Level leak test,
Dimensional issue Tie rod inspection from Checklist for stack assy Plenum Supporting locators to be
Alignment of MEA Tie rod dimension issue implemented during bundle Muttu M Closed
Customer: Customer Complaint 7 5 IQC QC/F/60 8 280 High build to avoid mis alignment 7 2 1 14 low
periodic validation Tool Periodic die validation
End User: Performance die
5 5 8 200 Medium 5 2 2 20 low
degradation
6 2 8 96 Low
leakage in bundles Checklist,work
Assembly : No impact 1 Improper packing 2 instruction QC-WI-20 8 16 Low
OCV Analysis
MEA Folding
Customer: Customer Complaint 1
Handling
2
&SOP and data record 8 16
Improper storege Proper storege facility Low
End User: Performance and method

1 2 8 16 Low
degradation
Next Process : No impact 4 2 Assembly as per 8 64 Low 4 3 1 12 low
Assembly : No impact 4 2 work instruuction QC- 8 64 Low 4 2 1 8 low
Customer: Customer Untrained operator WI-20 Bundle Level leak test,
8 2 8 128 Check list implimented 8 2 1 16
Flipped MEA Complaint-leads short circuit O2 number position mismatch High Ramesh T Closed Closed low
QC-F-60
OCV analysis and data record
End User: Performance Failure 8 2 8 128 High 8 2 2 32 low
Assembly : No impact 1 Untrained Operator 2 8 16 Low
work instructionQC-WI-
Dimensional issue 100% Sampling inspection
GDL Allignment Customer: Customer complaint 6 2 20 &SOP from IQC
8 96 Low
Trained operator
6 2 8 96 Low
degradation
Sub-assembly of 8 cell Next Process : no impact 1 3 8 24 Low
bundle [ Assembly of Assembly : No impact 1 Untrained Operator 2 8 16 Low
BPP, PTL. Gasket, MEA, GDL flipped Customer: no impact 1 no identification on top& bottom 3
Work instruction QC- 100% inspection during 8 24 Low
Gasket, and GDL as per
20 WI-20 &SOP assembly
the sequence of Stack End User: Performance
5 2 8 80 Low
bundle assembly degradation
checklist by aligning all
24 tierods] Next Process : Leads to
5 2 8 80 Low 5 3 1 15 low
leakage in bundles
Assembly : No impact 1 1 8 8 Low 1 2 1 2 low
Gasket poor packing methods supplier inspection 100% Sampling inspection better Standard implemented
Condition(wrinkl damage during transportation Muttu M 3/31/2023 Closed
es&damage) Customer: Customer complaint 8 4 report from IQC 8 256 High Quantity reduced in one packet. 8 2 1 16 low

8 4 8 256 High 8 2 2 32 low
degradation

5 1 8 40 Low 5 1 5 25 low
leakage in bundles * Scan cards to be implemented
Assembly : Bundles cannot be for short term.
7 Untrained Operator 2 Work instruction QC- 8 112 High 7 2 2 28 low
assembled further. Bar code scanner purchased on
100% inspection during
Gasket missing WI-20 Assembly
8th march trails are being Akshay 3/31/2023 Closed
Customer: Customer Complaint 8 3 SOP 8 192 High caarried out in MEA& gluing line 8 3 3 72 low
* MES System implementation.
End User: Performance * Bar-codes to be implemented.
8 3 8 192 High 8 3 2 48 low
degradation
5 2 8 80 Low 5 3 1 15 low
leakage in bundles
Assembly : No impact 1 Untrained Operator 2 8 16 Low 1 2 1 2 low
work instruction QC-WI-
Dimensional issue 100% Sampling inspection Out going dimensional check for
PTL Allignment Customer: Customer complaint 8 2 20 &SOP from IQC
8 128 High all PTLs Suraj Rawat 3/31/2023 Closed 8 2 1 16 low
Trained operator
8 2 8 128 High 8 2 2 32 low
degradation

6 2 1 12 Low 0
in bundles Work instruction QC-
O Ring missing in Un trained operator
leak test fixture Assembly : no impact. 1 2 WI-21 &SOP 100% inspection 1 2 Low 0
Customer: no impact 1 2 Trained operator 1 2 Low 0
End User: No impact 1 2 1 2 Low 0
Next Process : leads eratic
reading
6 1 2 12 Low 15.03.2023 Closed 4 3 2 24 Low
Assembly : no impact. 1 Untrained Operator 1 Work instruction QC- 2 2 Low 1 2 3 6 Low
Cable no coding on each
CVM lead miswired Customer: no impact 1 cable coding not available 1 WI-21 &SOP quick disconnectors 1 1 Low Build procedure implimented Suraj Rawat 8 3 2 48 Low
End User: Performance for OCV analysis
8 1 1 8 Medium 8 3 4 96 Low
degradation
leakage in Stack
6 2 1 12 Low 15.03.2023 Closed 0
8 Cell bundle Assembly : impact. 7 2 work instruction QC-WI- 1 14 Medium 7 1 1 7 Low

Guide pins impimented in 4
shifting(Mis
alignment of Improper handling 21 &SOP 100% Inprocess inspection corners to avoid mis-alignment Akshy/Ekarjun
Trained operator duirng shifting of bundles
gasket) Customer: Customer complaint 6 2 1 12 Low 6 2 1 12 Low

6 2 1 12 Low 6 2 1 12 Low
degradation
reading
6 1 2 12 Low 15.03.2023 Closed 6 1 2 12 Low
Assembly : no impact. 1 Untrained Operator 1 Work instruction QC- 2 2 1 1 2 2 Low
improper Testing Low Work instruction QC-WI-21 &
Load Customer: no impact 1 1
WI-21 & 100% Visual inspection 1 1 SOP
Akshy/Ekarjun
1 1 1 1 Low
Low
SOP
8 1 1 8 Medium 8 1 1 8 Low
degradation
Next Process : Impact 6 5 2 60 Medium 0 Low
Assembly : No impact 1 Untarined Operator 5 build procedure Resistance check using 2 10 Low 0 Low
Cells work instruction QC-WI- multimeter.
Customer: impact 8 BPP plates warpage 5 2 80 0
contact(cell High Low
shorting)
uneven loading 21 &SOP Resistance check
End User: Performance IQC of BPP QC-F-60
8 5 2 80 High 0 Low
degradation
5 3 2 30 Low Closed 4 3 2 24 Low
LEAK TESTING OF 8 leakage in Stack
30
CELL BUNDLE Mis aligned gasket
checklists Capacitance &cell height
mis aligned MEA
Bundle leakage BPP plate damge work instruction QC-WI- Bundle Level leak test, measurements to be taken to
detect mis-alignment of
Akshay 15.03.2023
Improper loading 21 & sop MEA&gasket
LEAK TESTING OF 8
30
CELL BUNDLE Mis aligned gasket
Assembly : no impact. 1 3 checklists 3 9 Low Capacitance &cell height 1 2 3 6 Low
mis aligned MEA
Bundle leakage BPP plate damge work instruction QC-WI- Bundle Level leak test, measurements to be taken to
detect mis-alignment of
Akshay 15.03.2023
Customer: Customer complaint 8 Improper loading 3 21 & sop 8 192 High 8 3 2 48 Low
MEA&gasket
8 4 8 256 High 8 3 4 96 Low
degradation
Next Process :
Assembly :
Over board
Leakeage Customer:
degradation
6 1 1 6 Low 0
reading 100% IQC of fittings
Assembly : No effect 1 Fitting damage 2 before assembly 1 2 Low
leak test using soap solution
Fixture leakage SOP not followed
Customer: No effect 1 2 supplier inspection 1 2 Low
report
End User:No effect 1 2 1 2 Low

reading
6 1 IQC of fittings before 1 6 Low
Fitting damage assembly
Testing Nitrogen + leak test using soap solution
Assembly : No effect 1 SOP not followed 2 1 2 Low
1% H2 Pressure supplier inspection
Customer: No effect 1 2 1 2 Low
report
Quick disc 6 2 2 24 Low
reading Check during Sub
connector Connection after loading
connection(mis Assembly : No effect 1 Un trained operator 2 assembly 100% in process inspection 2 4 Low
wired) Customer: No effect 1 2 work instruction& SOP 2 4 Low
6 2 1 12 Low
reading following work
Flipped MEA 100% inspection & OCV data
OCV Check Assembly : No effect 1 Wrong connection of Quick disc connector 2 instruction QC-WI-21 record 1 2 Low
Customer: No effect 1 2 parameter & SOP 1 2 Low
Next Process : cross leak 5 2 2 20 Low
Assembly : Plates will not
6 2 2 24 Low
assemble properly
Kepton folding& heat shrink folding following work
Applying of kapton
Un even size of heat shrink
and heat shrink to Customer: Customer complaint 3 Uneven heating 2 instruction QC-WI-20 100% In process inspection 2 12 Low
Tie rod parameter & SOP
Un trained operator
END HARDWARE End User: Performance
3 2 2 12 Low
ARRANGEMENT & 40 degradation
GRAFOIL CALCULATION
Next Process : cross leak 5 2 2 20 Low 3 2 1 Low
Assembly : no impact 1 2 1 2 Low 1 2 1 Low
Supplier inspection for
Bus bar projection
from all ends
Customer: Customer complaint 8 flatness of bus bar 1 flatness at all sides IQC before assembly 2 16 Medium Inspection done at supplier end suraj rawat 8 4 3 Low
before assembly
8 2 1 16 Medium 8 2 2 32 Low
degradation
6 1 2 12 Low 6 1 2 Low
leakage
Alignment of Assembly : no impact. 1 Untrained Operator 2 1 2 Low Guide pins impimented in 4 1 2 1 Low
8Assembly of bundle
to main stack
Bundles in Stack handling issue work instruction QC-WI- 100% Visual inspection corners to avoid mis-alignment akshay/ekarjun 15.03.2023 Closed
Assemby Customer: Customer complaint 8 Disturbing of bundles while shifting 1 1 8 Medium duirng shifting of bundles 8 1 1 Low
20 & SOP
8 1 2 16 Medium 8 1 2 Low
degradation
Next Process : uneven
distribution of load leads to 7 1 Check loading in HMI 1 7 Medium
50 leakage or poor sealing
Untrained Operator screen Stack height check
2T pre-load Assembly : no impact 1 machine calibration 1 calibration machine leak test 1 1 Low
Customer: customer complaint 8 1 SOP& work instruction 1 8 Medium
QC-WI-20
8 1 1 8 Medium
degradation
Next Process :
Bus Bar Assembly :
Orientation Customer:
End User:

distribution of load leads to 6 3 2 36 Low 3 2 1 Low
leakage or poor sealing
Billeville washer, Assembly : no impact 1 3 SOP&work instruction 2 6 Low 1 2 1 Low
Un trained operator Billeville height checking
qty and 100% Visual inspection Akshay 15.03.2023 Closed
configuration QC-WI-20 QC-F-62
Customer: customer complaint 8 3 8 192 High 8 4 3 Low

8 3 8 192 High 8 2 2 32 Low
degradation
Loading Torquing and
Resistance Check Next Process : uneven
distribution of load leads to 6 2 2 24 Low 4 3 2 24 Low
60 B Torquing usage of
multiple time Assembly : no impact 1 Un trained operator 2 SOP&work instruction 100% Inprocess inspection 2 4 Low MRP location created and scrap
Akshay 15.03.2023 Closed
1 2 3 6 Low
used Teflon QC-WI-20 IQC Inspection materials moved in ERP.
coated nut Customer: customer complaint 8 2 2 32 Medium 8 3 2 48 Low

8 2 2 32 Medium 8 3 4 96 Low
degradation
distribution of load leads to 6 1 1 6 Low 0 Low
Untrained Operator periodic calibration of torque check using torque
high & low Torque Assembly : no impact 1 instruments calibration 2 dial indicator 1 2 Low Torque dial indicator used to 1 2 3 6 Low
of stack torquing sequence instrumenrt Stack height check verify the required torque
Customer: customer complaint 8 2 SOP&work instruction leak test 1 16 Medium 8 3 2 48 Low
QC-WI-20
8 1 1 8 Medium 8 3 4 96 Low
degradation
Next Process : Performance
8 2 1 16 Medium 0 Low
degradation
build procedure 100% resistance check using
Assembly : no impact 1 1 2 2 Low 0 Low
60C-Shorting of
Cell contact
BPP plates warpage work instruction QC-WI- multimeter
Resistance check
cells Customer: customer complaint 8 uneven loading 2 20 &SOP implemented during bundle 1 16 Medium 0 Low
IQC of BPP build
8 1 1 8 Medium 0 Low
degradation
Next Process : Leads to leakage Mis aligned gasket

8 3 8 192 High Capacitance & Cell height 8 3 1 24 low
in Quad stack mis aligned MEA checklist
Stack leak test measurements be to taken to
Stack leak BPP plate damge implementation detect mis-alignment of MEA &
Assembly : No impact. 1 Improper loading 2 work instruction& sop 2 4 Low 1 2 1 2 low
Customer / End User : gasket
Customer complaint - 8 3 8 192 High 8 2 1 16 low
Leak testing of stack 70 Performance degradation
6 1 1 6 Low
reading IQC of fittings before
Fitting damage assembly
Assembly : No effect 1 1 leak test using soap solution 1 1 Low
Fixture leakage SOP not followed
supplier inspection
Customer / End User : No effect 1 1
report 1 1 Low
Suraj Rawat Suraj Rawat Malini C
PREPARED BY REVIEWED BY APRROVED BY

10
Severity Rating Scale

Rating Description
Hazardous
10
without warning
Hazardous With
9
Warning
8 Very high
7 High
6 Moderate
5 Low
4 Very Low
3 Minor
2 Very Minor
1 None
00000014
Definition (Severity of Effect)
Possibility of injury or violation of law without Warning
Possibility of injury or violation of law with Warning
Operation of the system is broken down without compromising the

safety
Operation of the system may be continued, but its performance is

affected
Operation of the system is continued, but its performance is

degraded
Performance of the system is affected seriously, and the

maintenance is needed
Performance of the system is less affected, and the maintenance

may not be needed
System performance and satisfaction with minor effect
System performance and satisfaction with a slight effect
No effect
00000015
Rating Description
Hazardous
10
without warning
Hazardous With
9
Warning
8 Very high
7 High
6 Moderate
5 Low
4 Very Low
3 Minor
2 Very Minor
1 None
00000016
Definition (Severity of Effect)
Failure could injure the customer or an employee.
Failure would create noncompliance with federal or local

regulations.
Failure renders the unit inoperable or unfit for use
Failure causes a high degree of customer dissatisfaction.
Failure results in a subsystem or partial malfunction of the product.
Failure creates enough of a performance loss to cause the

customer to complain.
Failure can be overcome with modifications to the customer’s

process or product, but there is minor performance loss.
Failure would create a minor nuisance to the customer, but the

customer can overcome it without performance loss.
Failure may not be readily apparent to the customer, but would

have minor effects on the customer’s process or product.
Failure would not be noticeable to the customer and would not

affect the customer’s process or product.
00000017
00000018
Occurrence Rating Scale
Rating Description
10 Exteremely High: Failure is almost inevitable.
Very High: Failures occur almost as often as
9
not.
8 Repeated failures.
7 High: Failures occur often.
6 Moderately High: Frequent failures.
5 Moderate: Occasional failures.
4 Relatively Low: Infrequent failures.
3 Low: Relatively few failures.
2 Remote: Failures are few and far between.
1 Exteremely Rare
00000019
Rating Scale
Potential Failure Rate
Greater than or equal to 1 in 2
1 in 3
1 in 8
1 in 20
1 in 80
1 in 400
1 in 2,000
1 in 15,000
1 in 150,000
Less than 1 in 150,000
00000020
Design Detection Rating Scale
Rating Description
10 Absolutely impossible
9 Very remote
8 Remote
7 Very low
6 Low
5 Moderate
4 Moderately high
3 High
2 Very High
1 Almost certain
00000021
esign Detection Rating Scale
Definition
The product is not inspected or the defect caused by failure is not detectable.
Product is sampled, inspected, and released based on Acceptable Quality Level

(AQL) sampling plans.
Product is accepted based on no defectives in a sample.
Product is 100% manually inspected in the process.
Product is 100% manually inspected using go/no-go or other mistake-proofing

gauges.
Some Statistical Process Control (SPC) is used in process and product is final
inspected off-line.
SPC is used and there is immediate reaction to out-of-control conditions.
An effective SPC program is in place with process capabilities (Cpk) greater than
1.33.
All product is 100% automatically inspected.
The defect is obvious or there is 100% automatic inspection with regular calibration
and preventive maintenance of the inspection equipment.
00000022
00000023
Severity Occurrence Detection Action Priority
3-1 9-10 8-10 Medium
4-7 Medium
1-3 Medium
7-8 8-10 Medium
4-7 Low
1-3 Low
5-6 8-10 Low
4-7 Low
1-3 Low
3-4 8-10 Low
4-7 Low
1-3 Low
1-2 8-10 Low
4-7 Low
1-3 Low
Critical
High
Medium
Severity Occurrence Detection Action Priority Low
1 1 1 Low
2 1 1 Low
1 2 1 Low
1 1 2 Low
3 1 1 Low
1 3 1 Low
1 1 3 Low
4 1 1 Low
2 2 1 Low
1 4 1 Low
2 1 2 Low
1 2 2 Low
1 1 4 Low
5 1 1 Low
1 5 1 Low
1 1 5 Low
6 1 1 Low
3 2 1 Low
2 3 1 Low
1 6 1 Low
3 1 2 Low
1 3 2 Low
2 1 3 Low
1 2 3 Low
1 1 6 Low
1 7 1 Low
00000024
1 1 7 Low
4 2 1 Low
2 4 1 Low
1 8 1 Low
4 1 2 Low
2 2 2 Low
1 4 2 Low
2 1 4 Low
1 2 4 Low
1 1 8 Low
3 3 1 Low
3 1 3 Low
1 3 3 Low
1 1 9 Low
5 2 1 Low
2 5 1 Low
5 1 2 Low
1 5 2 Low
2 1 5 Low
1 2 5 Low
1 1 10 Low
6 2 1 Low
4 3 1 Low
3 4 1 Low
2 6 1 Low
6 1 2 Low
3 2 2 Low
2 3 2 Low
1 6 2 Low
4 1 3 Low
2 2 3 Low
1 4 3 Low
3 1 4 Low
1 3 4 Low
2 1 6 Low
1 2 6 Low
2 7 1 Low
1 7 2 Low
2 1 7 Low
1 2 7 Low
5 3 1 Low
5 1 3 Low
1 5 3 Low
3 1 5 Low
1 3 5 Low
4 4 1 Low
2 8 1 Low
00000025
4 2 2 Low
2 4 2 Low
1 8 2 Low
4 1 4 Low
2 2 4 Low
1 4 4 Low
2 1 8 Low
1 2 8 Low
6 3 1 Low
3 3 2 Low
6 1 3 Low
3 2 3 Low
2 3 3 Low
1 6 3 Low
3 1 6 Low
1 3 6 Low
2 1 9 Low
1 2 9 Low
5 4 1 Low
5 2 2 Low
2 5 2 Low
5 1 4 Low
1 5 4 Low
4 1 5 Low
2 2 5 Low
1 4 5 Low
2 1 10 Low
1 2 10 Low
3 7 1 Low
1 7 3 Low
3 1 7 Low
1 3 7 Low
1 8 3 Low
1 6 4 Low
1 4 6 Low
1 3 8 Low
2 6 2 Low
2 4 3 Low
2 3 4 Low
2 2 6 Low
3 8 1 Low
3 4 2 Low
3 2 4 Low
3 1 8 Low
4 3 2 Low
4 2 3 Low
4 1 6 Low
00000026
6 4 1 Low
6 2 2 Low
6 1 4 Low
5 1 5 Low
1 5 5 Low
3 9 1 Low
3 3 3 Low
3 1 9 Low
1 3 9 Low
4 7 1 Low
2 7 2 Low
1 7 4 Low
4 1 7 Low
2 2 7 Low
1 4 7 Low
1 6 5 Low
1 5 6 Low
1 3 10 Low
2 5 3 Low
2 3 5 Low
3 10 1 Low
3 2 5 Low
3 1 10 Low
5 3 2 Low
5 2 3 Low
5 1 6 Low
6 1 5 Low
4 8 1 Low
4 4 2 Low
2 8 2 Low
4 2 4 Low
2 4 4 Low
1 8 4 Low
4 1 8 Low
2 2 8 Low
1 4 8 Low
1 7 5 Low
5 1 7 Low
1 5 7 Low
4 9 1 Low
6 3 2 Low
6 2 3 Low
4 3 3 Low
3 4 3 Low
2 6 3 Low
3 3 4 Low
6 1 6 Low
00000027
3 2 6 Low
2 3 6 Low
1 6 6 Low
4 1 9 Low
2 2 9 Low
1 4 9 Low
4 10 1 Low
5 4 2 Low
5 2 4 Low
2 5 4 Low
4 2 5 Low
2 4 5 Low
1 8 5 Low
5 1 8 Low
1 5 8 Low
4 1 10 Low
2 2 10 Low
1 4 10 Low
3 7 2 Low
2 7 3 Low
1 7 6 Low
6 1 7 Low
3 2 7 Low
2 3 7 Low
1 6 7 Low
5 3 3 Low
3 3 5 Low
5 1 9 Low
1 5 9 Low
6 4 2 Low
3 8 2 Low
4 4 3 Low
2 8 3 Low
6 2 4 Low
4 3 4 Low
3 4 4 Low
2 6 4 Low
4 2 6 Low
2 4 6 Low
1 8 6 Low
6 1 8 Low
3 2 8 Low
2 3 8 Low
1 6 8 Low
1 7 7 Low
5 2 5 Low
2 5 5 Low
00000028
5 1 10 Low
1 5 10 Low
3 9 2 Low
6 3 3 Low
3 3 6 Low
6 1 9 Low
3 2 9 Low
2 3 9 Low
1 6 9 Low
4 7 2 Low
2 7 4 Low
4 2 7 Low
2 4 7 Low
1 8 7 Low
3 10 2 Low
5 4 3 Low
5 3 4 Low
6 2 5 Low
4 3 5 Low
3 4 5 Low
2 6 5 Low
5 2 6 Low
2 5 6 Low
6 1 10 Low
3 2 10 Low
2 3 10 Low
1 6 10 Low
3 7 3 Low
3 3 7 Low
4 8 2 Low
4 4 4 Low
2 8 4 Low
4 2 8 Low
2 4 8 Low
2 7 5 Low
5 2 7 Low
2 5 7 Low
4 9 2 Low
6 4 3 Low
3 8 3 Low
6 3 4 Low
6 2 6 Low
4 3 6 Low
3 4 6 Low
2 6 6 Low
4 2 9 Low
2 4 9 Low
00000029
5 3 5 Low
4 10 2 Low
5 4 4 Low
4 4 5 Low
2 8 5 Low
5 2 8 Low
2 5 8 Low
4 2 10 Low
2 4 10 Low
3 9 3 Low
4 7 3 Low
2 7 6 Low
6 2 7 Low
4 3 7 Low
3 4 7 Low
2 6 7 Low
3 10 3 Low
6 3 5 Low
5 3 6 Low
5 2 9 Low
2 5 9 Low
4 8 3 Low
6 4 4 Low
4 4 6 Low
2 8 6 Low
6 2 8 Low
2 6 8 Low
2 7 7 Low
5 4 5 Low
5 2 10 Low
2 5 10 Low
5 3 7 Low
4 9 3 Low
6 3 6 Low
6 2 9 Low
2 6 9 Low
4 4 7 Low
2 8 7 Low
4 10 3 Low
6 4 5 Low
5 4 6 Low
6 2 10 Low
2 6 10 Low
6 3 7 Low
5 4 7 Low
6 4 6 Low
6 4 7 Low
00000030
Notes:
This is a general movement in the indsutry to go away from using the RPN as a method of
Prioritizing which item to work on, and move an Action Priority Level, consisisting of 3, 4 or 5
levels.
In this case 4 seperate levels were identified: Critical, High, Medium, Low.
Why was the change made?
Some quality professionals have pointed out (for many years) that using the RPN to determine the
priority of potential risks to tackle is a flawed approach.
The RPN is determined by multiplying the "Severity x Occurrence x Detection (or S x O x D)"
rankings; while this methodology has 1000 possible values there is only 120 unique values for the
RPN value.
Unfortunately, these 120 unique values are not evenly distributed across the range of 0-1000.
Some RPN scores will group up to 24 different (posssibly widely varying )scenarios into the same
score.
159 The discrimination can distort the importance of one potential risk relative to another.
252 And additionally, when the RPN is used to determine a rank order of action plans, some "severe"
280 potential risks (with a Severity ranking of 9 or 10) may not get the attention that they should
because low Occurrence and Detection rankings may drop the RPN below an actionable level.
308
FALSE The Automotive Industry Action Group (AIAG) and the Verband der Automobilindustrie (VDA)
FALSE jointly released an updated FMEA handbook on April 2, 2019. One of the major changes with the
FALSE new AIAG-VDA FMEA process is the use of the RPN has been eliminated. The RPN has been
replaced by an action priority (AP) table.
FALSE
FALSE The AIAG-VDA Manual states that the RPN method overlooks "rational logic" thereby
FALSE allowing some combinations of S, O and D to be overlooked when mitigation action plans should
FALSE have been initiated.
FALSE
Don Wheeler, author, statistician and well-respected legend in the Quality field wrote about the
FALSE shortcomings of the RPN in Quality Digest in 2011.
FALSE
FALSE --------------
FALSE The general table (to the right) is a rough cut to categorize the risk levels for different RPN values.
Use, modify, adapt it to fit your company's FMEA and/or the product you make.
FALSE
FALSE Unfortunately the General table and the table for Vlooup are not linked. If you want to update the
FALSE Vlook up Table, use the filters to quickly sort according to the preferred category and change the
FALSE Action Priority in the Vlookup Table.
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
00000031
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
00000032
he RPN as a method of
el, consisisting of 3, 4 or 5
m, Low.
using the RPN to determine the
Detection (or S x O x D)"

only 120 unique values for the
across the range of 0-1000.

ying )scenarios into the same
relative to another.
of action plans, some "severe"
attention that they should
below an actionable level.
Automobilindustrie (VDA)
of the major changes with the
nated. The RPN has been
onal logic" thereby

mitigation action plans should
Quality field wrote about the
levels for different RPN values.

ct you make.
nked. If you want to update the

rred category and change the
00000033
FMEA Procedure
Starting with Step 1: One can summarize the FMEA procedure
• Identify all Functions within scope. 1 Review all subsystems to do a list of the
• Identify how each Function can fail (Failure Modes). 2 Brainstorm potential failure modes asso
• Identify a group of associated Effects for each Failure Mode.
• Identify a Severity rating for each Effect group that prioritizes the 3 List the probable failure effects of each c
Failure Mode(s).
For each failure mode:
Step 1 of the Working Model is completed by considering appropriate 4 Assign an Occurrence rating using the Ta
Recommended Actions to:
• Eliminate the Failure Mode 5 Assign a Detection Rating using the Table
• Mitigate the Effect 6 Assign a Severity rating using the Table
Special emphasis on possible actions is required when Severity is 9 or 7 Calculate the failure mode RPN. RPN = S
10. Lower Severities may also be considered for actions. 8 Develop an action plan to address the hi
To eliminate failure mode(s), consider this action:
• Change the design (e.g., geometry, material) if related to a product 9 Take corrective action, and;
characteristic. 10 Reevaluate the RPN number after the ac
If the Failure Mode cannot be eliminated, continue with the Working
Model Step 2.
Two assumptions should be used when developing Causes in a

Design FMEA.
Assumption 1: The item is manufactured/assembled within engineering
specifications.
If following Assumption 1, identify potential Cause(s) of each Failure
Mode by asking:
• What could cause the item to fail in this manner?
• What circumstance(s) could cause the item to fail to perform its
function?
• How or why can the item fail to meet its engineering intent?
• What can cause the item to fail to deliver its intended function?
• How can interacting items be incompatible or mismatched? What
specifications drive compatibility?
Examples for Assumption 1 include:

• Material porosity specification too high for application
• Edge radius designed too sharp for export market
• Material hardness specified too low
• Lubricant specified too viscous
• Actual stress load higher than assumed load
• Torque specified too low
• Too close to adjacent part
• Incorrect material specified
• Inadequate design life assumption
• Incorrect algorithm
• Sneak path (unwanted circuit)
• Improper EMC/RFI design
• Component parameter degradation or drift
• Excessive heat 00000034
• Lubricant specified too viscous
• Actual stress load higher than assumed load
• Torque specified too low
• Too close to adjacent part
• Incorrect material specified
• Inadequate design life assumption
• Incorrect algorithm
• Sneak path (unwanted circuit)
• Improper EMC/RFI design
• Component parameter degradation or drift
• Excessive heat
Assumption 2: Assume the design may include a deficiency that may

cause unacceptable variation (e.g., misbuilds, errors) in the
manufacturing or assembly process.
Review past design deficiencies that have caused manufacturing or
assembly misbuilds that in turn have caused a Failure Mode.
If following Assumption 2, identify potential design deficiencies
(Causes) by asking:
• Is orientation or alignment important to how the item will function?
• Can the component be assembled upside down or backwards?
• Are the engineering specifications/tolerances compatible with the
manufacturing processes?
• What possible Causes may be identified by reviewing the
P-Diagram noise factors?
If design deficiencies are identified that may cause unacceptable
manufacturing/assembly variation, then they should be listed and
remedial design actions should be taken. Information on
manufacturing/assembly variability should be communicated to the
responsible manufacturing/assembly activity.
Examples of Assumption 2 include:

• Specifying a material heat treatment such that some material (on
the high side of the tolerance limit) cannot be machined to conform
to specification
• A symmetrical design that allows a part to be installed backwards
• Item installed upside down because design is symmetrical
• Torque incorrect because access hole is designed off-location
• Wrong fastener used because design is similar to standard
fastener also in use
00000035
summarize the FMEA procedure in 10 main steps. They are:
ll subsystems to do a list of the main items and their components;
m potential failure modes associated with each component;
robable failure effects of each component to each subsystem;
failure mode:
n Occurrence rating using the Table
Detection Rating using the Table
Severity rating using the Table
the failure mode RPN. RPN = Severity X Occurrence X Detection
an action plan to address the highest RPN;
rective action, and;
te the RPN number after the actions are completed.
00000036
PFMEA REVISION HISTORY
Part Name:- Customer :-
Part No & Rev - Model :-
Sign
Sr No Last Rev Latest Rev Review Date Revision History / Description Remarks
Engg QA Prod
01 ----- 00 05.11.2023 Initial FMEA made
July 2023 Status
Risk Count Status New Risk Status
Sections
Total Open Closed % Risk Total Open Closed % Risk
6 4 2 66.67% #REF! #REF! #REF! #REF!
44 0 44 0.00% #REF! #REF! #REF! #REF!
#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!
Total #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

uly 2023 Status
Open Risk Status Open Risk - Departmentwise
High Medium Low Design Mfg Quality Process Maintenance Tooling NPI Stores
2 2 0 0 0 0 3 0 1 0 0
0 0 0 0 0 0 0 0 0 0 0
#REF! #REF! #REF! #REF! #REF! #REF! 4 #REF! #REF! ### #REF!
#REF! #REF! #REF! #REF! #REF! #REF! 7 #REF! #REF! ### #REF!

NT MFG f03 Process Fmea

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Doc. No. : NT-MFG-F03 RISKs Open Closed PFD NT-QA-F12 Process Flow Daigram.xlsx (sharepoint.

Next Process : Fitment / Finsh Issue 6 3 Packaging done as per 5 90 Low 0

Next Process : Poor or non-uniform Under

Probablity of having raw material

Next Process : No Effect 4 5 5 100 Medium 0

Next Process : No Effect 4 5 5 100 Medium 0

Next Process : 5 5 5 125 Medium 0

Next Process : 5 5 Trained Manpower as 5 125 Medium

Next Process : 5 5 5 125 Medium 0

Customer / End user : 5 5 5 125 Medium 0

Next Process : 5 5 5 125 Medium 0

Assembly : 5 5 5 125 Medium 0

Customer / End user : 5 5 5 125 Medium 0

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Next Process : Viscocity of solution can

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Customer / End User: Customer

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Customer / End User: Customer

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PREPARED BY REVIEWED BY APRROVED BY

Next Process : No Impact 1 2 8 16 Low

Next Process : No Impact 2 1. Not covered in Supplier Report 2 8 32 Low

Next Process : Leeds to leakage

1. Not covered in Supplier Report

Next Process : Leads to leakage

Next Process : Impact 6 2 8 96 Low

Next Process : Impact 7 2 8 112 High Suraj from

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