Synergy Steels Limited

PROCESS FMEA
ITEM : Process Responsibility : Prepared By : FMEA No. : SSL/PFMEA/01
Model : Key Date : FMEA Date (Org) : Rev. / Date : 00/ 14.01.2019
Target RPN= 200
Core Team :

Potential Causes / Resp. &

Detect

Detect
Occur

Occur
Process Function Potential Failure Potential Effect (s) of Current Process Control Current Process Recommended Action

RPN

RPN
Sev

Sev
Mechanism of Target
Requirement Mode Failure (Prevention) Control (Detection) Action (s) Taken
Failures Comp.Date

Rolling Mill
Skilled Operator,
Display the DGM
Issues in rolling mill Continuous online
Size setting Improper Size Product Rejected 7 4 Standard Setup 2 56 standarad set up (Prodn),15th Completed 7 2 2 28
setup inspection by qualified
on the shop floor Feb'19
inspector

Senior furnace operators

Standardized furnace
Improper reheating with sufficient job
temperature set up for Display the DGM
Surface defects in furnace temperature, Bad knowledge,
Finished goods quality Product Rejected 8 3 various material grades, 3 72 standarad set up (Prodn),15th Completed 8 2 2 32
Material condition of mill passes. Visual inspection of
Strictly following the agreed on the shop floor Feb'19
passes by skilled
schedule for pass changes
operator

Improper setting , Poor

Regular calibration of Use EN 10088-3
condition of the UTM, Skilled Operator ,Automatic Sr. Manager
Tesnile testing of finished Tensile properties out UTM, Chemistry for chamistry &
Product Rejected 7 Improper 1 control of annealing furnace, 2 14 QC, 15th Completed 7 0 1 0
goods of tolerances validation by calibrate the
chemistry,Improper heat Standardized chemistry Feb'19
Spectrometer UTM machine
treatment

Temp. display of temp. Grade wise

Annealing
Variation in material Variation In Temp. of Auto Temp. Control controller/ regular temprature chart
Heat Treatment High / Low Temp. 6 1 2 12 Operater 15th Completed 6 1 1 6
properties Annealing Furnace available calibration of and WI available
Feb'19
thermocouples on shop floor

Visual inspection
Unskilled Operator , Regular Inspection as of every coils QC Line
Visual Inspection of Chances of passing of Skilled QC inspector
Defects in Product 3 Not able to detect the 3 per guidelines, 5 45 and work Inspecter 15 Completed 3 2 3 18
finished goods rejected Material Available
hidden defects instruction on th FEB'19
finishing area

Colour coding for coil Color Code chart

Coil QC Supervisor
Improper Marking Material Mixing 2 Un Skilled Operator 3 Skilled Operator identification, Hand held 7 42 on coil handling Completed 2 1 5 10
identification/traceability 15 th feb'19
Spectrometer and finishing area.

Skilled Operator , Stuffing Skilled operator Rachid Belt after Dispatch

Material damage during Un Skilled Operator, Bad
Improper Packing 8 3 the container with proper Supervision during 2 48 three line and last Supervisor Completed 8 2 1 16
Transit stuffing in the container
props & supports container stuffing line of coils 16th Feb'19

Packing & Dispatch

Ensure the loaded Dispatch
Check truck
vehicles leave SSL after Supervisor and
Improper transport Before entered and
Chances of Product Failure 8 Mishandling of material 3 Agreements with Transporter verifying that the loaded 2 48 Security Completed 8 2 1 16
activities material covered
material is in proper Incharge 15 th
with Tarpoline
condition Feb'19