AGRO ENGINEERING

POTENTIAL FAILURE MODE AND EFFE

Part Name:- ARM BRAKE PEDAL KEY CONTACT PERSON:- Mr. Anil Vijaya
Part No.:- 49612-76M00 CONTACT NO:- 9711117309
CHANGE LEVEL NO.:
SUPPLIER NAME & ADDRESS:- M/S Agro
PROJECT : YL-7
CUSTOMER :- M/s, MARUTI SUZUKI INDI
PROTOTYPE PRELAUNCH PRODUCTION
CORE TEAM:-Mr. Arvind Raghav,M

OCCUR.
PROCESS FUNCTION / POTENTIAL FAILURE POTENTIAL EFFECT(S) OF CURRENT PROCESS

SEV.
POTENTIAL CAUSE(S) /
REQUIREMENTS MODE FAILURE MECHANISM(S) OF FAILURE CONTROL PREVENTION

- WILL EFFECT SURFACE FINISH & -INCOMING INSPECTION STD. &

5 - IMPROPER STORAGE/ PACKING. 1
LIFE OF COMPONENTS. STORE / PACKING PROCEDURE
APPEARANCE
- APPEARANCE DETERIORATION / - IMPROPER STORAGE/ PACKING. - INCOMING INSPECTION STD. &
(RUST, SCRATCH & 6 1
CUSTOMER DISSATISFACTION. STORE / PACKING PROCEDURE
PITS ON SHEET)
- NON-APPLICATION OF RUST
1 - STORE / PACKING PROCEDURE
PREVENTIVE OIL

- PACKING AND INSPECTION NOT - INCOMING INSPECTION STD. &

6 1
-REDUCED STRENGTH / LIFE OF PROPER / MIX-UP. STORE / PACKING PROCEDURE
COMP. / CUSTOMER
THICKNESS OF SHEET DISSATISFACTION.
ARE NOT AS PER - P.O. PLACED WRONG 1 - ORDER CHECK SHEET.
(10) INCOMING (RAW DRAWING. (U/S OR O/S)
MATERIAL) - PACKING AND INSPECTION NOT - INCOMING INSPECTION STD. &
INSPECTION BOP - TOOL DAMAGE 5 2
PROPER / MIX-UP. STORE / PACKING PROCEDURE

- MATERIAL PROPERTIES
-REDUCED STRENGTH/ LIFE OF
-IMPROPER PHYSICAL OR CHECKED FROM THIRD PARTY
COMP. / CUSTOMER 6 2
CHEMICAL PROPERTIES . (M/S STAR WIRE) & INSPECTION
DISSATISFACTION.
OF BILL MATERIAL
PHYSICAL & CHEMICAL - P.O. PLACED WRONG. 1 - ORDER CHECK SHEET.
PROPERTIES IS NOT AS
PER STD. - MATERIAL PROPERTIES
- IMPROPER PHYSICAL OR CHECKED FROM THIRD PARTY
- TOOL DAMAGE 5 2
CHEMICAL PROPERTIES. (M/S STAR WIRE) & INSPECTION
OF BILL MATERIAL

- P.O. PLACED WRONG. 1 - ORDER CHECK SHEET.

-INSUFFICIENT AWARNESS /
- STORE PROCEDURE &
- WILL EFFECT SURFACE FINISH. 4 NEGLIGENCE OF OPERATOR / 1
MATLS MAY BE OVER LOAD OPERATOR / WORKERS TRAINING.
WORKER.
IN TROLLY.
 MATLS MAY BE OVER LOAD
IN TROLLY.
- TROLLY DESIGNED AS PER
-FATIGUE TO OPERATOR / WORKER. 5 - IMPROPER DESIGNED TROLLY. 1
PACKING STD.
(20) STORAGE - IMPROPER STORAGE,
MATLS MAY BE NOT - WILL EFFECT SURFACE FINISH & - STORE PROCEDURE &
5 NON-APPLICATION OF 1
COVERED IN POLYTHENE. LIFE OF COMPONENTS. OPERATOR / WORKERS TRAINING.
RUST PREVENTIVE OIL

- IMPROPER STORAGE,
-APPEARANCE POOR (DUST &
4 NON-APPLICATION OF
RUST)
RUST PREVENTIVE OIL
- STORE PROCEDURE &
2
OPERATOR / WORKERS TRAINING.

LENGTH NOT AS PER TRANNING PROVIDED TO

SPECIFICATION
WILL EFFECT NEXT OPERATION 5 OPERATOR MISTAKE 5
OPERATOR

WIDTH NOT AS PER TRANNING PROVIDED TO

SPECIFICATION
WILL EFFECT NEXT OPERATION
(30) SHEARING
- POOR APPEARANCE.
BURRS
-MAY CAUSE INJURY TO
WORKMEN / FINAL USER
5 OPERATOR MISTAKE 2
OPERATOR
- IMPROPER CLEARANCE - PROCESS CHART PROVIDED
5 2
BETWEEN PUNCH & DIE OPERATION WISE ON EACH
MACHINE & OPERATOR TRAINING.
- IMPROPER CLEARANCE
6 2 '-DIE SETTING PROCEDURE
BETWEEN PUNCH & DIE

- IMPROPER CLEARANCE - PROCESS CHART PROVIDED

- POOR APPEARANCE. 5 2
CRACK, WRINKLE, BETWEEN PUNCH & DIE OPERATION WISE ON EACH
THINNING, SCRATCH, MACHINE & OPERATOR TRAINING.
OBSERVED. -MAY CAUSE INJURY TO - IMPROPER CLEARANCE
6 2
WORKMEN / FINAL USER BETWEEN PUNCH & DIE '-DIE SETTING PROCEDURE
(40) BLANK PROFILE NOT AS PER REF. -WILL EFFECT NEXT OPERATION / -IMPROPER LOCATION WITH
5 2 - PROCESS CHART PROVIDED
SAMPLE / DRAWING . FITMENT PROBLEM. LOCATOR. OPERATION WISE ON EACH
MACHINE & OPERATOR TRAINING.
-PUNCH WORN OUT / DAMAGE. 2
'-DIE SETTING PROCEDURE
 AGRO ENGINEERING
POTENTIAL FAILURE MODE AND EFFE
Part Name:- ARM BRAKE PEDAL KEY CONTACT PERSON:- Mr. Anil Vijaya
Part No.:-49812-76M00 CONTACT NO:- 9711117309
CHANGE LEVEL NO.:
SUPPLIER NAME & ADDRESS:- M/S Agro
PROJECT : YL-7
CUSTOMER :- M/s, MARUTI SUZUKI INDI
PROTOTYPE PRELAUNCH PRODUCTION
CORE TEAM:-Mr. Arvind Raghav,M

OCCUR.
PROCESS FUNCTION / POTENTIAL FAILURE POTENTIAL EFFECT(S) OF CURRENT PROCESS

SEV.
POTENTIAL CAUSE(S) /
REQUIREMENTS MODE FAILURE MECHANISM(S) OF FAILURE CONTROL PREVENTION

- IMPROPER CLEARANCE - PROCESS CHART PROVIDED

BURRS - POOR APPEARANCE. 5 2 OPERATION WISE ON EACH
BETWEEN PUNCH & DIE
MACHINE & OPERATOR TRAINING.
-MAY CAUSE INJURY TO - IMPROPER CLEARANCE '-DIE SETTING PROCEDURE
6 2
WORKMEN / FINAL USER BETWEEN PUNCH & DIE
(50) BENDING
PROFILE NOT AS PER REF. -WILL EFFECT NEXT OPERATION / -IMPROPER LOCATION WITH - PROCESS CHART PROVIDED
5 2
SAMPLE / DRAWING . FITMENT PROBLEM. LOCATOR. OPERATION WISE ON EACH
MACHINE & OPERATOR TRAINING.

-PUNCH WORN OUT / DAMAGE. 2 '-DIE SETTING PROCEDURE

- IMPROPER CLEARANCE - PROCESS CHART PROVIDED

BURRS - POOR APPEARANCE.
-MAY CAUSE INJURY TO
WORKMEN / FINAL USER
5 2
BETWEEN PUNCH & DIE OPERATION WISE ON EACH
MACHINE & OPERATOR TRAINING.
- IMPROPER CLEARANCE '-DIE SETTING PROCEDURE
6 2
BETWEEN PUNCH & DIE

PROFILE NOT AS PER REF. -WILL EFFECT NEXT OPERATION / -IMPROPER LOCATION WITH - PROCESS CHART PROVIDED
5 2
SAMPLE / DRAWING . FITMENT PROBLEM. LOCATOR. OPERATION WISE ON EACH
MACHINE & OPERATOR TRAINING.
-PUNCH WORN OUT / DAMAGE. 2
'-DIE SETTING PROCEDURE

(60) PIERCING HOLES Ø & HOLES -CUSTOMER DISSATISFACTION. 6 -PUNCH WORN OUT / DAMAGE. 1
- PROCESS CHART PROVIDED
POSITION ARE NOT AS OPERATION WISE ON EACH
PER DRAWING.(U/S OR - FITMENT PROBLEM IN ASSY. 5 -PUNCH WORN OUT / DAMAGE. 1 MACHINE & OPERATOR TRAINING.

O/S) '-DIE SETTING PROCEDURE

- IMPROPER PRESSURE OF DIE
2
CUSHINE / SPRING .
 (60) PIERCING

-WILL EFFECT NEXT OPERATION / -IMPROPER LOCATION WITH

5 2 - PROCESS CHART PROVIDED
FITMENT PROBLEM. LOCATOR.
OPERATION WISE ON EACH
PROFILE NOT AS PER REF.
MACHINE & OPERATOR TRAINING.
SAMPLE / DRAWING .
-PUNCH WORN OUT / DAMAGE. 2
'-DIE SETTING PROCEDURE

-COMP. MAY HAVE

- IMPROPER DIE SETTING. - INSPECTION AS PER FINAL
SCRATCHES, WRINKLES,
-APPEARANCE PROBLEM. '- INSPECTION STD.
THINNING, FOLDING , 4 2
INSUFFICIENT AWARNESS / '- FINAL INSPECTION CHART
CRACKS, DENTS, BURRS,
NEGLIGENCY OF INSPETOR. & MASTER SAMPLE PROVIDED IN
DAMAGE ETC. .
INSPECTION AREA & INSPECTOR
TRAINING .

- IMPROPER MATLS. HANDLING 1

-PROFILE & HOLE

-FUNCTIONAL FAILURE AT - INSPECTED BY RECEIVING
POSITION NOT AS PER 6 - IMPROPER DIE SETTING 2
CUSTOMER END GAUGE / PANEL CHECKER.
REF. SAMPLE / DRAWING.
(70) INSPECTION
- FUNCTIONAL FAILURE AT
-OPERATION PUNCH BROKEN - FINAL INSPECTION CHART &
CUSTOMER END.
MASTER SAMPLE PROVIDED IN
6 1
INSPECTION AREA & INSPECTOR
MiXING OF COMPONENTS TRAINING .

PROFILE NOT AS PER REF. -WILL EFFECT NEXT OPERATION / -IMPROPER LOCATION WITH - PROCESS CHART PROVIDED
5 2
SAMPLE / DRAWING . FITMENT PROBLEM. LOCATOR. OPERATION WISE ON EACH
MACHINE & OPERATOR TRAINING.

-PUNCH WORN OUT / DAMAGE. 2 '-DIE SETTING PROCEDURE

RO ENGINEERING WORKS
E MODE AND EFFECTS ANALYSIS ( PFMEA )
NTACT PERSON:- Mr. Anil Vijayan FMEA NO:-
DATE:-
REV. NO.:- 00
R NAME & ADDRESS:- M/S Agro Engineering Works Plot No.36-38 Dlf Industrial Area Faridabad
REV. DATE:- -------
ER :- M/s, MARUTI SUZUKI INDIA LIMITED, GURGAON (HR). PAGE:- 01 OF 02
TEAM:-Mr. Arvind Raghav,Mr. Ramlal,Mr. Atul Jain,Mr. R.K Dubey

DETECT.
ACTION RESULTS

R. P. N.
RESPONSIBILITY &
CURRENT PROCESS RECOMMENDED
TARGET
CONTROL DETECTION ACTION(S)
COMPLETION DATE ACTIONS TAKEN S O D RPN
- 100% VISUAL INSPECTION BY
7 35
OPERATOR ON MACHINE.

- 100% VISUAL INSPECTION BY

7 42
OPERATOR ON MACHINE.

- 100% VISUAL INSPECTION BY

7 42
OPERATOR ON MACHINE.

- n=5 Pcs/LOT INSPECTED BY

5 30
VARIABL INSTRUMENTS.

- 100% VISUAL INSPECTION 7 42

- n=5 Pcs/LOT INSPECTED BY

5 50
VARIABL INSTRUMENTS.

- SUPPLIER CERTIFICATE PER

3 36
LOT

- 100% VISUAL INSPECTION 7 42

- SUPPLIER CERTIFICATE PER

3 30
LOT

- 100% VISUAL INSPECTION 7 35

- 100% VISUAL INSPECTION

7 28
INPROCESS
 - 100% VISUAL INSPECTION
7 35
INPROCESS

- 100% VISUAL INSPECTION

7 35
INPROCESS

- 100% VISUAL INSPECTION

7 56
INPROCESS

- 100% VISUAL INSPECTION

2 50
INPROCESS

- 100% VISUAL INSPECTION

2 50
INPROCESS

60
-INPROCESS INSPECTION 6

72

60
-INPROCESS INSPECTION 6
72

-INPROCESS INSPECTION 4 40

-INPROCESS INSPECTION 4 40
RO ENGINEERING WORKS
E MODE AND EFFECTS ANALYSIS ( PFMEA )
NTACT PERSON:- Mr. Anil Vijayan FMEA NO:-
DATE:-
REV. NO.:- 00
R NAME & ADDRESS:- M/S Agro Engineering Works Plot No.36-38 Dlf Industrial Area Faridabad
REV. DATE:- -------
ER :- M/s, MARUTI SUZUKI INDIA LIMITED, GURGAON (HR). PAGE:- 02 OF 02
TEAM:-Mr. Arvind Raghav,Mr. Ramlal,Mr. Atul Jain,Mr. R.K Dubey

DETECT.
ACTION RESULTS

R. P. N.
RESPONSIBILITY &
CURRENT PROCESS RECOMMENDED
TARGET
CONTROL DETECTION ACTION(S)
COMPLETION DATE ACTIONS TAKEN S O D RPN

60
-INPROCESS INSPECTION 6

72

-INPROCESS INSPECTION 4 40

-INPROCESS INSPECTION 4 40

60
-INPROCESS INSPECTION 6

72

-INPROCESS INSPECTION 4 40

-INPROCESS INSPECTION 4 40

-INPROCESS INSPECTION 5 30

-INPROCESS INSPECTION 4 20

-INPROCESS INSPECTION 4 40
-INPROCESS INSPECTION 4 40

-INPROCESS INSPECTION 4 40

- 100% VISUAL INSPECTION 7 56

28

- 100% INSPECTION 4 48

- 100% VISUAL INSPECTION 7 42

-INPROCESS INSPECTION 4 40

-INPROCESS INSPECTION 4 40