STRUCTURE ANALYSIS (STEP 2) Function Analysis (STEP 3)
1. Process Item 2. Process 1. Function of the 2. Function of the
System, Step Station 3. Process Work Process Item Process Step and
Subsystem,
No. and Name Function of System, Product
Part Element of Element Subsystem, Characteristic
or 4M Type
Name of Focus Part Element or (Quantitative value
Element Process is optional)
Process
Hydraulic OP. 190 Operator - Resting To drill a hole of given Drill Diameter
cylinder Drilling & Clamping Diameter & Depth Ø9.0 ± 0.2,
Rockshaft Ø10.0 ± 0.2
Machine - SPM,
speed, feed, DOC
Tool - Drill, Fixture,
Material- Hydraulic
Oil
Operator - Tool To maintain Drill Depth Drill Depth
Setting so as to obtain open hole 15.0 ±1.5,
in Next operation 16.5 ±1.5
Machine - SPM,
speed, feed, Stopper
Operator - Resting To maintain Distance of Centre Distance,
& Clamping holes as specified w.r.t. 120.5 & 131.0 ±0.2
Ø100 bore
Machine - SPM,
speed, feed
Tool - Drill, Fixture
Operator - Resting To maintain position of Φ 0.5
& Clamping Ø10 hole as specified
w.r.t. A,B
Machine - SPM,
speed, feed
Tool - Drill, Fixture
sis (STEP 3) Failure Analysis (STEP 4)
3. Function of the 1. Failure Effects (FE) 2. Failure Mode
Process Work to the Next Higher 3. Failure Cause (FC) of
Severity (S) of FE
(FM) of the
Element and Level Element and/or Focus Element the Work Element
Process End
Characteristic User
To Ensure Proper Product may have to be loose clamping
Resting & Clamping sorted and a portion (less 7
than 100%) scrapped;
Proper Speed , Feed, deviation from primary Improper Speed & feed
Depth of Cut process; decreased line 7
speed or added Oversize
Correct Drill Size , manpower. Wrong Drill Size,
Fixture Condition 7 Blunt Drill
Proper Hydraulic oil Inadequate Hydraulic oil
Level 7 level
100% of production run Drill Wear Out
may have to be reworked
off line and accepted 6
Undersize
Inadequate Hydraulic Oil
6 Level
Proper Offset & Tool 100% of production run Improper Offset & Tool
Setting may have to be reworked 6 Setting
off line and accepted
Proper Speed , Feed, Undersize Improper Speed & feed,
Depth of Cut, Stopper 6 Imrpoper Stopper
Condition Condition
To Ensure Proper
Resting & Clamping Improper Resting &
Clamping
8
Proper Speed , Feed, Improper Speed & feed,
Depth of Cut Line shutdown greater Distance out of
from 1 hour to full shift; specification
stop shipment possible; 8
Dowel Pins, Locator in field repair or replacement Dowel Pin, Locator Wear
Proper Condition required (Assembly to end Out
user) Other than for
regulatory noncompliance 8
To Ensure Proper
Resting & Clamping Improper Resting &
Clamping
8
Proper Speed , Feed, Improper Speed & feed,
Depth of Cut Position out of
Line shutdown greater specification
from 1 hour to full shift; 8
stop shipment possible;
Dowel Pins, Locator in field repair or replacement Dowel Pin, Locator Wear
Proper Condition required (Assembly to end Out
user) Other than for
regulatory noncompliance 8
RISK ANALYSIS (STEP 5)
Detection (D) of FC/FM
Special Characteristics
Occurrence (O) of FC
PFMEA AP
Current Detection
Current Prevention Controls (DC) of FC Prevention Action
Control (PC) o FC or FM
Work Instruction For resting Sampling Inspection
&clamping 3 6 M
Fixed RPM & Feed Sampling Inspection
3 6 M
Tool Life Chart, Drill Size Setup Approval, First
Monitoring of new Cutter 3 Piece Approval, 6 M
100% inspection &
Daily machine Checksheet Sampling
record Inspection
In PIR
3 6 M
Drill Change as per Sampling Inspection
Frequency, Drill Size
Monitoring After Re- 3 6 M
sharpening
Daily machine Checksheet Sampling Inspection
3 6 M
Work Instruction For tool Sampling Inspection
Setting & offset 3 6 M
Fixed speed & feed , Sampling Inspection
Frequent Check Of Stopper 3 6 M
Condition
Work Instruction For resting Sampling Inspection
&clamping 3 6 M
Fixed RPM & Feed Sampling Inspection
3 6 M
Frequent Check on Dowel Sampling Inspection
Pin, Locator condition 3 6 M
Work Instruction For resting Setup Approval, First
&clamping Piece Approval
3 6 M
Fixed RPM & Feed
3 6 M
Frequent Check on Dowel
Pin, Locator condition
3 6 M
OPTIMIZATION (STEP 6)
Target Action Taken
Responsible Completion
Detection Action Persons Name Completion Status with Pointer to Date
Date Evidence
Severity (S)
Occurrence (O)
Detection (D)
PFMEA AP
Special Characteristics
Remark
STRUCTURE ANALYSIS (STEP 2) Function Analysis (STEP 3)
1. Process Item
System, 2. Process 1. Function of the 2. Function of the
Step Station Process Item Process Step and
Subsystem, No. and Name 3. Process Work Function of System, Product
Part Element Element
or of 4M Type Subsystem, Characteristic
Focus Part Element or (Quantitative value
Name of Element Process is optional)
Process
Hydraulic OP. 220 Operator - Resting Finishing of Ø100 Bore Diameter
cylinder Honing & Clamping, Depth Ø100.060 ± 0.040
Rockshaft of cut
Machine- Honing
M/C, Speed , Feed
Tool - Honing sticks,
Fixture
Material- lapping
paper, Diesel,
Hydraulic Oil
Material- lapping
paper, Diesel,
Hydraulic Oil
Operator - Resting
& Clamping, Depth
of cut
Machine- Honing
M/C, Speed , Feed
Tool - Honing sticks,
Fixture
Material- lapping
paper, Diesel,
Hydraulic Oil
ysis (STEP 3) Failure Analysis (STEP 4)
1. Failure Effects (FE)
3. Function of the 2. Failure Mode
Severity (S) of FE
Process Work Element to the Next Higher (FM) of the
Level Element and/or
and Process End Focus Element
Characteristic
User
To Ensure Proper Resting
& Clamping, 8
To maintain Proper DOC
Line shutdown greater
from 1 hour to full shift;
Proper Speed , Feed stop shipment possible;
field repair or replacement 8 Oversize
required (Assembly to end
user) Other than for
Honing stick with proper regulatory noncompliance
Hardness value, Fixture 8
Condition
Proper cutting oil (Diesel)
level,
8
Adequate Hydraulic oil
level
Lapping Paper of proper
grade ,
8
Adequate Hydraulic oil
level
A portion Of the
To Ensure Proper Resting production run may have
& Clamping, to be reworked offline & 7
To maintain Proper DOC accepted
Proper Speed,Feed, Depth
7
of Cut
Honing stick with proper
Hardness value, Fixture 7 Undersize
Condition
Undersize
Lapping Paper of proper
grade ,
Proper cutting oil (Diesel)
level, 7
Adequate Hydraulic oil
level
is (STEP 4) RISK ANALYSIS (STEP 5)
Detection (D) of FC/FM
Occurrence (O) of FC
PFMEA AP
3. Failure Cause (FC) of Current Detection
the Work Element Current Prevention Controls (DC) of FC
Control (PC) o FC or FM
Loose Clamping,
Improper DOC due to error Work
Instruction for resting, 4
clamping &Scale reading Sampling Inspection 6 M
in Scale reading,
Improper Speed, Feed Fixed Speed , Feed ,
Parameter. 3 Sampling Inspection 6 M
Hardening of honing sticks, Setup Approval, First Piece
Improper fixture condition Approval
3 Sampling Inspection 6 M
Manual Control & 100 %
Inadequate cutting oil flow, verification
Inadequate hydraulic Oil 4 Sampling Inspection 6 M
level
Setup Approval, Daily
machine Checksheet
Paper with different Grade,
Inadequate hydraulic Oil 3 Sampling Inspection 6 M
level
Loose Clamping,
Improper DOC due to error Work
Instruction for resting, 3
clamping &Scale reading Sampling Inspection 6 M
in Scale reading,
Fixed Speed , Feed ,
Improper Speed, Feed Parameter. 3 Sampling Inspection 6 M
Hardening of honing sticks, Setup Approval, Tool life
Improper fixture condition Monitoring Chart
3 Sampling Inspection 6 M
Setup Approval, Daily
machine Checksheet
Paper with different Grade,
Inadequate cutting oil flow,
Inadequate hydraulic Oil 3 Sampling Inspection 6 M
level
OPTIMIZATION (STEP 6)
Special Characteristics
Responsible Target
Prevention Action Detection Action Completion
Persons Name Date Status
To control cutting oil Precontrol chart PBR 25.01.2020 Inprocess
flow through PLC logic.
N (STEP 6) Remark
Occurrence (O)
Detection (D)
Severity (S)
PFMEA AP
Action Taken Completion
with Pointer to
Evidence Date
8 3 5 M
It was observed that
preventive controls are
adequate and the best
possible detective
control established so,
no action required in
order to reduce AP.
