POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS

Part Number 20014296 - Process Responsibility Mr. Shibu John FMEA Number SMPL/PFMEA/TAURUS-91 Rev. No 0

Part Name Extractor Rod Key Date 11.01.2023 Prepared By Mr. Vilas Mohurle

Core Team SJ, VM, AG, SS, RJ Customer Name Taurus FMEA Date (Orig) 15.01.2023

Responsibility Action Results

Potential Cause(s) / Current Process Recomme
Process Potential Failure Current Process Control & Target
Operation Requirement Potential Effect(s) of Failure Sev. Class mechanism (s) of Occ. Controls Det. RPN nded
No. Mode Prevention Completion Actions
Failure Detection Action(s) Sev Occ Det RPN
Date Taken

Wrong Material 1. Mill TC

Quality plan not Material procurement from
receipt / Improper NP - Nil 6 3 veification at 6 108
followed by supplier approved source
Material receipt stage

2. Third party
SAE 1213 SP - Nil
material test
NTT 115

CE - Part Failure

EU - Less part life

Not as per Process SOP not Material procurement from Receipt

Inclusion NTT 115 NP- Nil 6 3 6 108
specifications followed by supplier approved source Inspecion
Reciept 120 to 240 HB (70 SP- Tool may break the tool
10 Hardness
Inspection to 100 HRB). in next operation
ferrite + perlite
Matrix CE-Nil
uniform distributed.

Carbide Uniform distributed EU-Nil

Grain size 5 to 8 ASTM E 112

Bend, damage, NP- May remain unclean in Process SOP not Material procurement from Receipt
3 3 6 54
crack etc. next operation followed by supplier approved source Inspecion

SP- Nil
Free from visual surface defects
CE-Nil

EU-Nil

1. Set up
NP-Nil 1. Setting error 1. Setting work instructions
approval report,
2. Inprocess
SP-Nil 2. Tool worn out 2. Tool change frequency
Inspection
Oversize 4 3 6 72
CE-May cause functional
and fitment issue

EU-Nil
Turning and
20 OD Ø5.40-0.06
Parting
1. Set up
NP-Nil 1. Setting error 1. Setting work instructions
approval report,
2. Wrong offset 2. Inprocess
SP-Nil 3. Work instructions
Undersize 4 correction 3 Inspection 6 72
CE-May cause functional
and fitment issue

EU-Nil
 Responsibility Action Results
Potential Cause(s) / Current Process Recomme
Process Potential Failure Current Process Control & Target
Operation Requirement Potential Effect(s) of Failure Sev. Class mechanism (s) of Occ. Controls Det. RPN nded
No. Mode Prevention Completion Actions
Failure Detection Action(s) Sev Occ Det RPN
Date Taken
1. Set up
NP-Nil 1. Setting error 1. Setting work instructions
approval report,
2. Inprocess
SP-Nil 2. Tool worn out 2. Tool change frequency
Inspection
Oversize 5 3 5 75
CE-May cause functional
and fitment issue

EU - Less part life

OD Ø4.8
1. Set up
NP-Nil 1. Setting error 1. Setting work instructions
approval report,
2. Inprocess
SP-Nil 2. Tool worn out 2. Tool change frequency
Inspection
Undersize 5 3 5 75
CE-May cause functional
and fitment issue

EU - Less part life

1. Set up
NP-Nil 1. Setting error 1. Setting work instructions
approval report,

SP-Nil 2. Tool worn out 2. Tool change frequency

Oversize 7 3 6 126
CE-May cause functional
and fitment issue

Turning and EU-Nil

20 Radius R7.5
Parting
1. Set up
NP-Nil 1. Setting error 1. Setting work instructions
approval report,

SP-Nil 2. Tool worn out 2. Tool change frequency

Undersize 7 3 6 126
CE-May cause functional
and fitment issue
EU-Nil

1. Set up
NP-Nil 1. Setting error 1. Setting work instructions
approval report,

SP-Nil 2. Tool worn out 2. Tool change frequency

Oversize 4 3 6 72
CE-May cause fitment issue

EU-Nil
OD Ø5.95+0.1
1. Set up
NP-Nil 1. Setting error 1. Setting work instructions
approval report,
2. Wrong offset
SP-Nil 3. Work instructions
Undersize 4 correction 3 6 72
CE-May cause fitment issue

EU-Nil
 Responsibility Action Results
Potential Cause(s) / Current Process Recomme
Process Potential Failure Current Process Control & Target
Operation Requirement Potential Effect(s) of Failure Sev. Class mechanism (s) of Occ. Controls Det. RPN nded
No. Mode Prevention Completion Actions
Failure Detection Action(s) Sev Occ Det RPN
Date Taken
1. Set up
NP-Nil 1. Setting error 1. Setting work instructions
approval report,
SP-Nil 2. Wrong tool
Oversize 4 3 6 72
CE-May cause fitment issue 3. Tool blunt 3. Tool change frequency

EU-Nil
Cross
(Pitch 0.5 x 30°)
knurning 1. Set up
NP-Nil 1. Setting error 1. Setting work instructions
approval report,
SP-Nil
Undersize 4 3 6 72
CE-May cause fitment issue

EU-Nil
1. Set up
NP-Nil 1. Setting error 1. Setting work instructions
approval report,
2. Inprocess
SP-Nil
Inspection
Oversize 6 3 6 108
CE-May cause functional
issue
EU-Less part life
Dim. 1.50
1. Set up
NP-Nil 1. Setting error 1. Setting work instructions
approval report,
2. Inprocess
SP-Nil
Turning and Inspection
20 Undersize 6 3 6 108
Parting
CE-May cause fitment issue

EU-Nil
1. Set up
NP-Nil 1. Setting error 1. Setting work instructions
approval report,
2. Inprocess
SP-Nil 2. Tool worn out 2. Tool change frequency
Surface Inspection
Ra 1.6 High 6 3 6 108
Roughness CE-May cause functional
and fitment issue
EU-Nil
1. Set up
NP-Nil 1. Setting error 1. Setting work instructions
approval report,
2. Inprocess
SP-Nil 2. Wrong tool
Inspection
Oversize 4 3 6 72
CE-May cause functional
and fitment issue
EU-Nil
Radius R0.1
1. Set up
NP-Nil 1. Setting error 1. Setting work instructions
approval report,
2. Inprocess
SP-Nil 2. Tool worn out 2. Tool change frequency
Inspection
Undersize 4 3 6 72
CE-May cause functional
and fitment issue
EU-Nil
 Responsibility Action Results
Potential Cause(s) / Current Process Recomme
Process Potential Failure Current Process Control & Target
Operation Requirement Potential Effect(s) of Failure Sev. Class mechanism (s) of Occ. Controls Det. RPN nded
No. Mode Prevention Completion Actions
Failure Detection Action(s) Sev Occ Det RPN
Date Taken
1. Set up
NP-Nil 1. Setting error 1. Setting work instructions
approval report,
SP-Nil
Oversize 4 3 6 72
CE-May cause functional
and fitment issue
EU-Nil
Dim. 26.0
1. Set up
NP-Nil 1. Setting error 1. Setting work instructions
approval report,
SP-Nil
Undersize 4 3 6 72
CE-May cause functional
and fitment issue
EU-Nil
1. Set up
NP-Nil 1. Setting error 1. Setting work instructions
approval report,
SP-Nil
Oversize 5 3 5 75
CE-May cause functional
and fitment issue
EU-Nil
Length 51.5±0.1
1. Set up
NP-Nil 1. Setting error 1. Setting work instructions
approval report,
SP-Nil
Undersize 5 3 5 75
CE-May cause functional
and fitment issue
Turning and EU-Nil
20
Parting
1. Set up
NP-Nil 1. Setting error 1. Setting work instructions
approval report,
2. Inprocess
SP-Nil 2. Tool worn out 2. Tool change frequency
Inspection
Oversize 6 3 5 90
CE-May cause functional
and fitment issue
EU-Nil
Total Length 57±0.2
1. Set up
NP-Nil 1. Setting error 1. Setting work instructions
approval report,
2. Inprocess
SP-Nil 2. Tool worn out 2. Tool change frequency
Inspection
Undersize 6 3 5 90
CE-May cause functional
and fitment issue
EU-Nil
1. Set up
NP-Nil 1. Wrong tool 1. Setting work instructions
approval report,
SP-Nil 2. Tool worn out 2. Tool change frequency
Oversize 6 3 5 90
CE-May cause functional
and fitment issue
EU-Nil
Thread
6.00
Length 1. Set up
NP-Nil 1. Wrong tool 1. Setting work instructions
approval report,
SP-Nil
Undersize CE-May cause functional 6 3 5 90
and fitment issue
EU-Nil
 Responsibility Action Results
Potential Cause(s) / Current Process Recomme
Process Potential Failure Current Process Control & Target
Operation Requirement Potential Effect(s) of Failure Sev. Class mechanism (s) of Occ. Controls Det. RPN nded
No. Mode Prevention Completion Actions
Failure Detection Action(s) Sev Occ Det RPN
Date Taken
1. Set up
NP-Nil 1. Setting error 1. Setting work instructions
approval report,
2. Inprocess
SP-Nil 2. Tool worn out 2. Tool change frequency
Inspection
Oversize 6 3 5 90
CE-May cause functional
and fitment issue
EU-Nil
Turning and
20 Thread M4 x 0.5 ESQ
Parting 1. Set up
NP-Nil 1. Setting error 1. Setting work instructions
approval report,
2. Inprocess
SP-Nil
Inspection
Undersize 6 3 5 90
CE-May cause functional
and fitment issue
EU-Nil
1. Set up
NP-Nil 1. Setting error 1. Setting work instructions
approval report,
2. Inprocess
SP-Nil 2. Excess collet r/o 2. To check collet r/o
Inspection
Run Out 0.05 Excess 4 3 6 72
CE-May cause functional
and fitment issue
EU-Nil
1. Set up
NP-Nil 1. Setting error 1. Setting work instructions
approval report,
2. Inprocess
SP-Nil 2. Tool worn out 2. Tool change frequency
Turning and Inspection
20 Oversize 4 3 6 72
Parting CE-May cause functional
and fitment issue
EU-Nil
OD 4-0.05
1. Set up
NP-Nil 1. Setting error 1. Setting work instructions
approval report,
2. Inprocess
SP-Nil
Inspection
Undersize 4 3 6 72
CE-May cause functional
and fitment issue
EU-Nil

Stage
30 100% Inspection by measuring instruments and gauges
Inspection

ST process parameter Process parameter

NP-Nil
disturbed at supplier monitoring

SP-Nil Incorrect inspection Skill matrix of inspector

Surface Chrome Free from surface Presence of surface
40 6 3 Test report 6 108
Treatment Plating defects defects
CE- Customer dissatisfaction

EU-Less part life

 Responsibility Action Results
Potential Cause(s) / Current Process Recomme
Process Potential Failure Current Process Control & Target
Operation Requirement Potential Effect(s) of Failure Sev. Class mechanism (s) of Occ. Controls Det. RPN nded
No. Mode Prevention Completion Actions
Failure Detection Action(s) Sev Occ Det RPN
Date Taken

Final
50 100% Inspection by measuring instruments and gauges
Inspection

Excess qty. packing Customer dissatisfaction 6 2 6 72

Short qty.packing Customer dissatisfaction 6 2 Packing 6 72

Packing SOP not
60 Packing Qty. per box, Packing slip Packing SOP verification
followed
Wrong part packing Customer dissatisfaction 8 2 visually 6 96

Packing slip missing Customer dissatisfaction 4 2 6 48

Prepared By: A. Gokhe Apprved By:- V Mohurle