PROCESS FMEA - PACKING & DESPATCH

POTENTIAL ACTION RESULTS

POTENTIAL POTENTIAL CURRENT RESPONSIBILITY /
PROCESS FUNCTION CAUSE(S) RECOMMMNEDED
FAILURE EFFECT OF S C O PROCESS D RPN TARGET DATE FOR
REQUIREMENTS MECHANISM OF ACTIONS/ REMARKS ACTION
MODE FAILURE CONTROL COMPLETION S O D RPN
FAILURE TAKEN

PACKING &
DESPATCH:
Counting of
After completion all the
Variation in forgings are
operation and Customer Improper Counting
Quantity with 5 MA 3 properly recorded 2 30 NIL NIL
inspection, forgings are Dissatisfied of forgings
Delivery note before Delivery
despatched to the
note was raised
customer by road in
loose

Prepared By : Approved By :
 PROCESS FMEA - FINAL INSPECTION

POTENTIAL ACTION RESULTS

POTENTIAL POTENTIAL CURRENT RESPONSIBILITY /
PROCESS FUNCTION CAUSE(S) RECOMMMNEDED
FAILURE EFFECT OF S C O PROCESS D RPN TARGET DATE FOR
REQUIREMENTS MECHANISM OF ACTIONS/ REMARKS ACTION
MODE FAILURE CONTROL COMPLETION S O D RPN
FAILURE TAKEN

FINAL INSPECTION;
Inspectors are
After completion of all Approval of May affect
provided with
the process, forgings wrong customer 8 MA Unksilled Inspector 2 2 32 NIL NIL
sufficent on job
are offered for pre component fitment
training
despatch inspection

Prepared By : Approved By :
 PROCESS FMEA - COINING

POTENTIAL ACTION RESULTS

POTENTIAL POTENTIAL CURRENT RESPONSIBILITY /
PROCESS FUNCTION CAUSE(S) RECOMMMNEDED
FAILURE EFFECT OF S C O PROCESS D RPN TARGET DATE FOR
REQUIREMENTS MECHANISM OF ACTIONS/ REMARKS ACTION
MODE FAILURE CONTROL COMPLETION S O D RPN
FAILURE TAKEN

COINING;
Shot blasted
forgings are coined in 7 Straightness May affect First off / Last off
Improper die
ton coining hammer in may not be customer 8 MA 2 and Patrol 2 32 NIL NIL
design
order to achieve the achieved fitment Inspection
required flatness and
straightness

Prepared By : Approved By :
 PROCESS FMEA - SHOT BLASTING

POTENTIAL ACTION RESULTS

POTENTIAL POTENTIAL CURRENT RESPONSIBILITY /
PROCESS FUNCTION CAUSE(S) RECOMMMNEDED
FAILURE EFFECT OF S C O PROCESS D RPN TARGET DATE FOR
REQUIREMENTS MECHANISM OF ACTIONS/ REMARKS ACTION
MODE FAILURE CONTROL COMPLETION S O D RPN
FAILURE TAKEN

SHOT BLASTING:
After the forgings ate
Forgings are
heat treated, scale
Inadequate inspected
formed on the surface Poor Surface
removal of Inadequate Visually 100% for
of the forgings are finish, Customer 5 MA 2 3 30 NIL NIL
scales from process time good surface
removed by shot Dissatisfaction
forgings finish before
blasting operations
unloading
using the wheelabrator
machine

Prepared By : Approved By :
 PROCESS FMEA - HEAT TREATMENT

POTENTIAL ACTION RESULTS

POTENTIAL POTENTIAL CURRENT RESPONSIBILITY /
PROCESS FUNCTION CAUSE(S) RECOMMMNEDED
FAILURE EFFECT OF S C O PROCESS D RPN TARGET DATE FOR
REQUIREMENTS MECHANISM OF ACTIONS/ REMARKS ACTION
MODE FAILURE CONTROL COMPLETION S O D RPN
FAILURE TAKEN
HEAT TREATMENT;
Normalising - Load the 1.Oil Healer is
forgings in the furnance installed.
to the tempurature 2. Cleaning of
range of 880 to 920 Surface Oil spillage from
burners in regular
Deg Cel. & after Over Heat roughness and 7 MI burner into the 2 3 42 NIL NIL
intervals
reching the set Grain growth furnance
3. Visual check
tempurature, soaking up of burning by
time of 45 min. will be the operators
given for uniformity. On
Completion of soaking
time, forgings are Variation of
Tempurature
unloaded from the hardness, grain
controllers,
furnance and air cooled Improper structure Tempurature not
Thermocouples,
variation, 7 MI maintained as per 2 2 28 NIL NIL
heating Tempurature
Physical specification
recorders are
properties
installed
variation

Prepared By : Approved By :
 PROCESS FMEA - FETTLING

POTENTIAL ACTION RESULTS

POTENTIAL POTENTIAL CURRENT RESPONSIBILITY /
PROCESS FUNCTION CAUSE(S) RECOMMMNEDED
FAILURE EFFECT OF S C O PROCESS D RPN TARGET DATE FOR
REQUIREMENTS MECHANISM OF ACTIONS/ REMARKS ACTION
MODE FAILURE CONTROL COMPLETION S O D RPN
FAILURE TAKEN
FETTLING; Processed
and insected forgings
are fetteled before heat Insuffecient 100% jobs are
May affect
treatment. In fettling inspected by
removal of customer 8 MA Unskilled operator 2 2 32 NIL NIL
excess trimming burrs trimming burr inspectors for
fitment
are removed proper fetling

Prepared By : Approved By :
 PROCESS FMEA - FORGING & FORGING INSPECTION

POTENTIAL ACTION RESULTS

POTENTIAL POTENTIAL CURRENT RESPONSIBILITY /
PROCESS FUNCTION CAUSE(S) RECOMMMNEDED
FAILURE EFFECT OF S C O PROCESS D RPN TARGET DATE FOR
REQUIREMENTS MECHANISM OF ACTIONS/ REMARKS ACTION
MODE FAILURE CONTROL COMPLETION S O D RPN
FAILURE TAKEN
FORGING:
Sheared billets are
heated in the furnace Excess flow of oil
and forged using the May lead to 2 Every one hour
to furnace
inspected and approved formation of Pit billet tempurature
die Excess heating
marks, scales 6 MA was inspected 3 36 NIL NIL
of billets
on forging and recorded for
surface its conformance
Excess heating
2
time

FORGING:
Sheared billets are Less flow of oil to
heated in the furnace 2 Every one hour
furnace
and forged using the May lead to billet tempurature
Less heating of
inspected and approved billets unfillings in 7 MA was inspected 3 42 NIL NIL
die blocks. Forging is forgings and recorded for
done by Flattening, Less heating time 2 its conformance
Rolling, Moulding,
Finishing and Trimming
& Piercing operation
Leads to On Every die
Low heating of component setting the die
3 MI Less heating time 2 2 12 NIL NIL
die blocks Catch up with block tempurature
die is inspected

Dimesion May affect Insufficent stokes 2 First off / Last off 32 NIL NIL
variation in customer 8 MA and Patrol 2
forging fitment Inspection
Improper Trimming
2 32 NIL NIL
tool setting

FORGING Inspectors are

Approval of May affect
INSPECTION; All provided with
wrong customer 8 MA Unksilled Inspector 2 2 32 NIL NIL
processed forgings are sufficent on job
component fitment
subjected for inspection training
by first off / last off,
patrol inspection and
visual inspection
 PROCESS FMEA - DIE INSPECTION

POTENTIAL ACTION RESULTS

POTENTIAL POTENTIAL CURRENT RESPONSIBILITY /
PROCESS FUNCTION CAUSE(S) RECOMMMNEDED
FAILURE EFFECT OF S C O PROCESS D RPN TARGET DATE FOR
REQUIREMENTS MECHANISM OF ACTIONS/ REMARKS ACTION
MODE FAILURE CONTROL COMPLETION S O D RPN
FAILURE TAKEN
DIE INSPECTION:
Component drawing Die is approved
received from customer Approval of only after
Deviation in
is used to prepare the wrong Unkilled die inspecting the
component 4 MA 2 2 16 NIL NIL
die drawing and the die dimesion inspector sample taken from
dimesion
was made according to the die in plaster
the die drawing. The of paris
made die is inspected
for its conformance as
per die drawing Designers are
Deviation in
Improper Die Unkilled die provided with
component 4 MA 2 2 16 NIL NIL
Design designer sufficent on job
dimesion
training

Prepared By : Approved By :
 PROCESS FMEA - RAW MATERIAL RECEIVING & CUTTING

POTENTIAL ACTION RESULTS

POTENTIAL POTENTIAL CURRENT RESPONSIBILITY /
PROCESS FUNCTION CAUSE(S) RECOMMMNEDED
FAILURE EFFECT OF S C O PROCESS D RPN TARGET DATE FOR
REQUIREMENTS MECHANISM OF ACTIONS/ REMARKS ACTION
MODE FAILURE CONTROL COMPLETION S O D RPN
FAILURE TAKEN
RAW MATERIAL
RECEIVING
INSPECTION;
Raw material is Raw material is
received from the inspected during
Mistake supply
customer approved Variation in the Variation in billet receiving and any
2 MI made by the RM 2 1 4 NIL NIL
sources and offered for section weight
supplier
deviation in
inspection section can be
detected easily

Raw material is
inspected for
Variation in Customer Mistake supply
chemical
chemical Requirements 8 MA made by the RM 2 1 16 NIL NIL
composition while
inspection cannot be meet supplier
receiving the
material
Any surface
Leads to
Improper detects can be
Surface surface craks or
7 MA Inspection by RM 3 detected in the 2 42 NIL NIL
Defects poor surface
Supplier RM receiving
finish
inspection
RAW MATERIAL
CUTTING:
Received and Improper First off / Last off
Inspected raw material setting of billet Variation in billet
2 MI Unskilled operators 2 and Patrol 2 8 NIL NIL
is sheared into billets in shearing weights
Inspection
cold shearing machine

Periodic
Defective tooling 3 maintenance of 1 27 NIL NIL
tooling
End burr Leads to crack
9 MA
formation or lapping
Variation of
2 RM inspection 1 18 NIL NIL
Hardness

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