PROCESS FMEA

PFMEA NUMBER. : PFMEA / EM / PAA 819 REVISION : 0 KEY CONTACT PERSON : BALAJI. P (DGM-MFG) DATE (ORIGINAL) : 03.06.2021
PART NUMBER : PAA 819 REVISION: A KEY CONTACT PHONE : 044-27163014
DATE (REVISED) : 01.09.2020
CUSTOMER PART NO.: 545-7489
CORE TEAM : QPT
PART NAME : DW16L x 26" CONSTRUCTION EQUIPMENT WHEEL CUSTOMER ENGG. APPROVAL / DATE ( If Reqd. ) : NIL
SUPPLIER / PLANT : M/s. WIL, SRIPERUMBUDUR KEY DATE : 02.11.2018 CUSTOMER QUALITY APPROVAL / DATE ( IF REQUIRED. ) : NIL
MODEL YEAR / VEHICLE(S) : VARIOUS WHEEL CODE : EAG 349 PREPARED BY : QPT
PROCESS RESPONSIBILITY : BALAJI. P (DGM-MFG) SUPPLIER CODE : - PRODUCTION : SPDC ASSEMBLY LINE
CURRENT PROCESS CONTROLS ACTION RESULT

CLASSIFICATI

DETECTION
SEVERITY

OCCURRENC

OCCURRENC

DETECTION
SEVERITY
POTENTIAL POTENTIAL RESPONSIBILITY & ACTION

RPN
PROCESS POTENTIAL EFFECT(S) RECOMMENDED

ON
OPN NO REQUIREMENT FAILURE CAUSE(S) OF TARGET

RPN
CONTROLS CONTROLS ACTION TAKEN
FUNCTION OF FAILURE

E
MODE FAILURE PREVENTION DETECTION COMPLETION DATE COMPLETION
DATE

NEXT PROCESS : NO EFFECT

CUSTOMER : FITMENT PROBLEM Excess interference/ excess First off, patrol and last off 100% runout
EXCESS RUN-OUT 6 Setup Instruction 4 5 120 ongoing ongoing
ENDUSER : DEGRADATION OF runout of components inspection, last off inspection inspection
PRIMARY FUNCTION
NEXT PROCESS : NO EFFECT
TOOL MARK / Misalignment of top & First off, patrol and last off
CUSTOMER : POOR APPEARANCE 7 Setup Instruction 2 6 84
DAMAGE ON DISC bottom tool inspection, 100% visual inspection
ENDUSER : POOR APPEARANCE
NEXT PROCESS : NO EFFECT
CUSTOMER : FITMENT PROBLEM First off, patrol and last off
INSET VARIATION 7 Improper setting Setup Instruction 2 6 84
ENDUSER : DEGRADATION OF inspection, 100% inspection
PRIMARY FUNCTION
PRESS DISC NEXT PROCESS : NO EFFECT
DISC TO BE
(PAD 496) INTO RIM CUSTOMER : DIFFICULTY IN
POSITIONED ON RIM MARKING NOT Improper setting / marking Set up instruction , Work First off, patrol and last off
10 BASE TRACEABILITY 3 2 6 36
WITHOUT FITMENT VISIBLE / LEGIBLE insert wear instruction inspection, 100% inspection
(PAR 111) AND TACK ENDUSER : DIFFICULTY IN
ISSUES
WELD & MARKING TRACEABILITY
NEXT PROCESS : NO EFFECT
CUSTOMER : DEGRADATION OF Wrong Rim fed to line, Alarm generation in
First off, patrol and last off
MIXUP OF RIM PRIMARY FUNCTION 7 15X24 & 16X24 rims are Colour coding of rims 4 7 196 robot at picking point Methods Engineer 10.03.2020 7 1 7 49
inspection, 100% inspection
ENDUSER : DEGRADATION OF difficult to distinguish from chute
PRIMARY FUNCTION

NEXT PROCESS : NO EFFECT Set up instruction , Work First off, patrol and last off LASER beam line
SUPERVISOR
VALVE HOLE CUSTOMER : DIFFICULTY IN FITTING 7 Operator skill inadequate instruction, welder qualification & 2 inspection, 100% inspection by 6 84 generator provided 19.11.2018 7 2 3 42
& COMPLETED
POSITION NOT AS OF VALVE skill matrix operator for valve hole location
PER DRAWING ENDUSER : DEGRADATION OF
PRIMARY FUNCTION Set up instruction , Work First off, patrol and last off
7 Improper setting 2 6 84
instruction inspection, 100% inspection

13 INSPECT

NEXT PROCESS : NO EFFECT

CUSTOMER : NO EFFECT Destructive testing once for every
WELD UNDERCUT 9 Wrong weld parameters Setup Instruction and WPS 2 5 90
ENDUSER : LOSS OF PRIMARY setting
FUNCTION
NEXT PROCESS : NO EFFECT
CUSTOMER : NO EFFECT Rust on the component and
WELD POROSITY 9 Setup Instruction and WPS 2 Visual Check - 100% 5 90
ENDUSER : LOSS OF PRIMARY wrong weld parameters
FUNCTION
NEXT PROCESS : NO EFFECT no slide repeatability
CUSTOMER : NO EFFECT Destructive testing once for every
BEAD SHIFT 9 Wire bend Operator Instruction. 2 5 90
ENDUSER : LOSS OF PRIMARY setting
FUNCTION Weld fixture run-out

NEXT PROCESS : NO EFFECT

Flux blockage Visual Check - 100%
BLOW HOLES / PIN CUSTOMER : NO EFFECT
9 Operator Instruction. 2 6 108
HOLES ENDUSER : LOSS OF PRIMARY
DISC AND RIM FUNCTION Rust on the component Visual Check - 100%
SHOULD BE JOINED
NEXT PROCESS : NO EFFECT
WITHOUT ANY MISS
ALIGNMENT & LESS WELD WAVINESS CUSTOMER : NO EFFECT Lack of rigidity of torch;
9 Setup Instruction 3 Visual Check - 100% 6 162
SAW DISC TO RIM ENDUSER : LOSS OF PRIMARY Lack of rigidity of slide
20 STRENGTH ▼
FUNCTION
 CURRENT PROCESS CONTROLS ACTION RESULT

CLASSIFICATI

DETECTION
SEVERITY

OCCURRENC

OCCURRENC

DETECTION
SEVERITY
POTENTIAL POTENTIAL RESPONSIBILITY & ACTION

RPN
PROCESS POTENTIAL EFFECT(S) RECOMMENDED

ON
OPN NO REQUIREMENT FAILURE CAUSE(S) OF TARGET

RPN
CONTROLS CONTROLS ACTION TAKEN
FUNCTION OF FAILURE

E
MODE FAILURE PREVENTION DETECTION COMPLETION DATE COMPLETION
DATE

NEXT PROCESS : NO EFFECT

LESS WELD CUSTOMER : NO EFFECT Destructive testing once for every
9 Wrong weld parameters Setup Instruction and WPS 1 5 45
PENETRATION ENDUSER : LOSS OF PRIMARY setting
FUNCTION
NEXT PROCESS : NO EFFECT
9 Wrong weld parameters Setup Instruction and WPS 2 Visual Check - 100% 5 90
WELD BURN CUSTOMER : LOSS OF PRIMARY
Manual cut off of weld in cut Timer provided for auto cut off of Destructive testing once for every
THROUGH FUNCTION 9 1 5 45
out wheels weld. setting & DP check
ENDUSER : LOSS OF PRIMARY
NEXT PROCESS : NO EFFECT Destructive testing once for every
LESS LEG LENGTH 9 Wrong weld parameters Setup Instruction and WPS 1 5 45
CUSTOMER : LOSS OF PRIMARY setting
FUNCTION
Destructive testing once for every
ENDUSER : LOSS OF PRIMARY
LESS THROAT 9 Wrong weld parameters Setup Instruction and WPS 1 setting, First off, patrol and last off 5 45
FUNCTION
inspection
NEXT PROCESS : NO EFFECT
Destructive testing once for every
CRACK IN WELD CUSTOMER : NO EFFECT 9 Wrong weld parameters Setup Instruction and WPS 1 5 45
setting & DP check
ENDUSER : LOSS OF PRIMARY
NEXT PROCESS : NO EFFECT
WELD SAMPLE
DEFECTIVE CUSTOMER : NO EFFECT Weld requirement standard
PREPARATION AS 9 Measurement error 1 Report review by Lab incharge 5 45
SAMPLE APPROVAL ENDUSER : LOSS OF PRIMARY MD425
PER PROCEDURE
FUNCTION
Improper setting, wrong
MARKING MISSING 4 Setup Instruction 1 100% inspection 6 24
NEXT PROCESS : NO EFFECT positioning of product
SERIAL NUMBER UNIQUE SERIAL NO CUSTOMER : NO EFFECT
30 4 tip worn out Setup Instruction 1 100% inspection 6 24
MARKING & DATE LESS ENDUSER : NON-TRACEABILITY
INDENDATION DURING SERVICE Improper setting
4 Setup Instruction 1 100% inspection 6 24
(Less load)

NEXT PROCESS : NO EFFECT

Set up Instruction / Work First off,Patrol and Last off
TOOL MARK CUSTOMER : POOR APPEARANCE 3 Excess load / Tool wear 1 6 18
Instruction inspection
ENDUSER : POOR APPEARANCE

NEXT PROCESS : NO EFFECT

First off,Patrol and Last off
PLANISH NAVE TO MEET DRAWING BORE NOT TO CUSTOMER : FITMENT PROBLEM Set up Instruction / Work
40 7 Excess Load 1 inspection & 100% ensuring using 6 42
(IF REQUIRED) REQUIREMENTS SPECIFICATION ENDUSER : DEGRADATION OF Instruction
Bore locator of Run out fixture
PRIMARY FUNCTION

NEXT PROCESS : NO EFFECT

FLATNESS NOT TO CUSTOMER : FITMENT PROBLEM Set up Instruction / Work
7 Excess load / Less load 1 First off Inspection with CMM 6 42
SPECIFICATION ENDUSER : DEGRADATION OF Instruction
PRIMARY FUNCTION

NEXT PROCESS : NO EFFECT

CUSTOMER : FITMENT PROBLEM Excess interference/ excess First off, patrol and last off
EXCESS RUNOUT 7 Setup Instruction 2 6 84
ENDUSER : DEGRADATION OF runout of components inspection, 100% inspection
PRIMARY FUNCTION

NEXT PROCESS : NO EFFECT

CUSTOMER : FITMENT PROBLEM Excess interference/ excess First off, patrol and last off
EXCESS WOBBLE 7 Setup Instruction 2 6 84
ENDUSER : DEGRADATION OF runout of components inspection, 100% inspection
PRIMARY FUNCTION

NEXT PROCESS: NO EFFECT

CUSTOMER: FITMENT PROBLEM First off, patrol and last off
INSET VARIATION 7 Improper setting Setup Instruction 2 6 84
ENDUSER: DEGRADATION OF PRIMARY inspection, 100% inspection
FUNCTION

NEXT PROCESS: NO EFFECT

DIMENSIONS TO BE BORE NOT TO CUSTOMER: FITMENT ISSUE Setup Instruction, SPC, Parameter 100% check with running hub &
7 ▼ Wrong setting or tool wear 2 7 98
43 INSPECTION SPECIFICATION ENDUSER: LOSS OF PRIMARY check sheet peg
AS PER DRAWING
FUNCTION

NEXT PROCESS : NO EFFECT

BOLT HOLE PCD /
CUSTOMER : FITMENT ISSUE Improper cleaning of seating 100% check with running hub &
POSITION NOT TO 7 Setup Instruction 2 7 98
ENDUSER : LOSS OF PRIMARY and clamping areas peg
SPECIFICATION
FUNCTION

NEXT PROCESS : NO EFFECT

BOLT HOLE
CUSTOMER : FITMENT PROBLEM Cmm check for 1 no during first
POSITION NOT TO 7 Excess play of drill jig bush Setup Instruction, Work instruction 1 7 49
ENDUSER : DEGRADATION OF off inspection
SPEC
PRIMARY FUNCTION
 CURRENT PROCESS CONTROLS ACTION RESULT

CLASSIFICATI

DETECTION
SEVERITY

OCCURRENC

OCCURRENC

DETECTION
SEVERITY
POTENTIAL POTENTIAL RESPONSIBILITY & ACTION

RPN
PROCESS POTENTIAL EFFECT(S) RECOMMENDED

ON
OPN NO REQUIREMENT FAILURE CAUSE(S) OF TARGET

RPN
CONTROLS CONTROLS ACTION TAKEN
FUNCTION OF FAILURE

E
MODE FAILURE COMPLETION DATE
PREVENTION DETECTION COMPLETION
DATE

NEXT PROCESS : NO EFFECT

FLATNESS NOT TO CUSTOMER : FITMENT PROBLEM Improper setting of planishing Cmm check for 1 no during first
7 Setup Instruction, Work instruction 1 7 49
SPECIFICATION ENDUSER : DEGRADATION OF tool / Less load off inspection
PRIMARY FUNCTION

DP TEST FOR DISC

53
WELDING

NEXT PROCESS : NO EFFECT

POOR FINISH AT 100% inspection after wheel
CUSTOMER : POOR APPEARANCE 3 Improper dressing On the job training 2 8 48
WELD REGION dressing
ENDUSER : POOR APPEARANCE
DRESS BUTT JOINT TO MAINTAIN THE
NEXT PROCESS : NO EFFECT
AND PRODUCT FREE WELD PROJECTION 100% inspection after wheel
60 CUSTOMER : POOR APPEARANCE 3 Improper dressing On the job training 2 8 48
CIRCUMFERENTIAL FROM SURFACE HIGH dressing
ENDUSER : POOR APPEARANCE
WELDING OVER LAP WELD DEFECTS
NEXT PROCESS : NO EFFECT
100% inspection after wheel
WELD DEPRESION CUSTOMER : POOR APPEARANCE 3 Improper dressing On the job training 2 8 48
dressing
ENDUSER : POOR APPEARANCE
NEXT PROCESS : NO EFFECT
VALVE GUARD NOT CUSTOMER : FITMENT ISSUE Improper setting, wrong
TO BE POSITIONED 7 Setup Instruction 2 100% visual inspection 6 84
TO SPECIFICATION ENDUSER : LOSS OF PRIMARY positioning of product
AS PER DRAWING
VALVE GUARD FUNCTION
70 SPECIFICATION AND
WELDING
TO MATE WITH SUB NEXT PROCESS : NO EFFECT
ASSEMBLY WELD NOT TO Improper setting, wrong
CUSTOMER : NO EFFECT 7 Setup Instruction 2 100% visual inspection 6 84
SPECIFICATION positioning of product
ENDUSER : REDUCED PERFORMANCE

73 INSPECT

SHOTBLASTING /
80
PICKLING & OILING
DRESS SHARP EDGE,
DENT MARK, CUT
90
MARK & OTHER
DEFECTS

93 INSPECT

PRE-TREAT AND PAINT

100
AS PER COMP. DRG
Refer PFMEA/SPDR/PP/001,002,003 & 004
110 TOP COAT

INSPECTION &
113, 120
PACKING

125 STORE

DISTRIBUTION LOCATION : QPT

CC ▼ Critical characterstics
SC @ Special Characterstics
0 03.06.2021 INITIAL RELEASE
REV. REVISION
REVISION HISTORY
NO. DATE
REVIEWED AND FELIX PRASAD SAMPATH GIRI BALAMURUGAN DURAI
APPROVED BY : R&D TDN MFG QAD