PFMEA - Machining

Action Results
Occurrence
Detection
Occurrence
Severity
Responsibility
Detection
Class
Severity
Process Function Potential Failure Potential Cause(s) / Mechanism(s) Recommended
RPN
Opn Process Seq Potential Effects of Failure Current Process Controls prevention Current Process Controls detection and target
RPN
Requirements Mode. of Failure Actions* Actions taken
completion date
OPERATION NO. #10 Receive casting
6 3
Down stream operation :
100% parts may have to be reworked 5 Casting damage 3 Dedicated trolley with separator
offline
1) To meet the Assy :
1 Fettling Not done properly 3 Trained Operator
customer Damage when receive NA
200% checked by inspector 6 108
specification for good part Customer :
part A Portion of production run may have to 6 Operator loading skill 2 Dedicated trolley with separator
be scrapped
End User:
5 While transportation 3 Standardised vehicle transport
Degradation of secondary function
During storage / Method of storage 3 Dedicated trolley with separator

10 Receive casting
6 3

100% parts may have to be reworked Component exposed to rain & not
5 2 Re shot blasting if exposed to rain
offline stored properly
2) No white rust White rust Assy : 200% checked by inspector 6 108

1 Improper storage Location 3 Allocated or Identified location
NA
Customer :
100% parts may have to be scrapped 6 Method of storage 3 Dedicated trolley with separator
End User:
1
No effect
OPERATION NO. #15 Shift Code Marking
6 3

Nil 1 Missing Operation 3 Machine interlinked with VMC
Assy :
No Date code. 1 Wrong setting 3 Allocated or Identified location
Nil
Customer :
Lack of traceability 6
End User:
Nil 1

NC on machining face 1 As cast flash 3 Pocket provited in restpad 1
15 Shift Code Assy :

Shift Punching 1 200% checked by inspector 6 108
Marking Casting projection in Nil
Resting place (R1) Customer :
Nil 6
End User:
Nil 1

Nil 1 Casting face flash /Projection 3 Insp. Done at casting stage
Location & orientation Assy :

Improber seating of mating part 1
hole as cast face
(OP20 setup 1 LHS & Customer :
RHS) Nil 6
End User:
Nil 1
OPERATION NO. #20 LEFT HAND SIDE & RIGHT HAND SIDE -1 SETUP
6 3
Down stream operation: Not able to
6 No machining Allowance 2 Insp. Done at casting stage
machine (non clearance)
Milling Height over size
Assy: NA 1 Wrong loading 3 Nil 6 108
Gauge checked by operator
Customer:Assembly problem 6 Uneven clamping 3 Preventive maintanence
Established tool change frequency and
End User: Nil 1 Inserts worn out 2
specify in Opn.std
1) Milling Height
31.00±0.25, wrong tool offset 2 Program locked
68.18 ±0.2, Established tool change frequency and
Build up edge 3
72.93 ±0.2, specify in Opn.std
3.57±0.25
6 3
Down stream operation: Nil 1 Bend in the casting 3 Insp. Done at casting stage
Milling Height under Guide pin available in fixture to guide the
Assy: NA 1 Wrong loading 3 Gauge checked by operator 6 108
size part while loading
Customer: May affect / disturb at
6 Uneven clamping 3 preventive maintanence
assembly
End User: Nil 1 wrong tool offset 2 Program locked
6 3
Opn:20A) Milling
Flatness Assy: NA 1 Uneven clamping 3 preventive maintanence

2) Flatness 0.1 First off Inspection 6 108
Out of spec
6 Rest pads not in same plane 3 Fixture designed as per drawing
assembly
End User: Nil 1 Wrong tool offset 2 Program locked
6 3
Coolant secondary filter provided &

Down stream operation: Nil 1 Coolant concentration 2 Before coolant top up, check coolant
concentricity through refractor meter
Surface finish out of Establish tool change frequency and
3) Surface finish Assy: NA 1 insert wear 2 Inspection by inspector as per QCPC 6 108
spec specify in Opn.std
Customer:
6 Less Coolant flow 2 Failsafe alarm available in machine
Leakage in assembly
Establish tool change frequency and
End User: Nil 1 Buildup edge 3
specify in Opn.std
Pressure indicator to check the clamping
Clamping pressure more or less 2
pressure
6 2
Down stream operation:
1 Build up edge 2 Tool life monitoring provided
2ndf setup dimensions not ok
Assy: NA 1 No machining Allowance 2 Insp. Done at casting stage Plug gauge check by operator. Diameter 6 72
I) Drill dia oversize is controlled within ± 0.05 for
Customer: Part strengthen not good while
6 Burr entrapment into tool holder 2 Coolant spray in tool holder further process control
running
End User: degradation of secondary
6 Wrong tool selection 2 Tool issue only as per tools list
function
1) Diameter Ø8.6 Spindle runout 2 preventive maintenance
6 2
1 Tool wear 2 Tool life monitoring provided
2nd setup machining cannot be done
Plug gauge check by operator. Diameter
II) Drill dia undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list is controlled within ± 0.05 for 6 72
further process control
Customer: Assembly cannot be done 6
End User: Nil 1
Down stream operation: Establish tool change frequency and

6 Drill wear 2
2nd setup machining cannot be done specify in Opn.std
20B) ø8.6 Drilling Assy: NA 1 wrong tool Offset 2 Program locked
2) Depth Not Through Plug gauge check by operator. 6 72
Customer: Assembly cannot be done 6 Tool broken 2 Tool breakage sensor to be provided
Component getting disturbed while Ensure proper clamping of component

End User: Nil 1 2
machining against resting as per OS
6 3
2nd setup operation cannot be done
3) Position (Datum C) Position Component getting disturbed while Ensure proper clamping of component
Assy: NA 1 2 Plug gauge check by operator. 5 90
0.25 wrt AB Out of spec machining against resting as per OS
Customer:
6
Cant able to assy the mating part
End User: Nil 1
6 2
Established cutting parameters and

Down stream operation:Nil 1 Tool drag 2
program locked
3) Perpendicularity Perpendicularity out of Component getting disturbed while Ensure proper clamping of component
Assy: NA 1 2 First off Inspection 6 72
0..3 spec machining against resting as per OS
Customer: Can't able to assemble, Bolt
6
may foul
End User: Nil 1
6 2
Thread cannot be formed
1
Action Results
Occurrence
Detection
Occurrence
Severity
Responsibility
Detection
Class
Severity
RPN
RPN
completion date
Assy: NA 1 No machining Allowance 2 Insp. Done at casting stage

I) Drill dia oversize Core plug gauge check by operator 6 72
6 Burr entrapment into tool holder 2 Coolant spray in tool holder
running
function
Spindle runout 2 preventive maintenance
6 3

Nil
1) Ø6 / ø7 drill
II) Drill dia undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list

Customer: Bolt will not enter 6 Spindle speed / Feed rate high 3
program locked
End User: Nil 1
6 3
Nil
20C) ø6.0/ø7
Drilling II) Drill dia undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Core plug gauge check by operator 6 108
program locked
End User: Nil 1
6 3
Down stream operation: Nil 1 Wrong tool offset 2 Program locked
l) depth Undersize Assy: Nil 1 Tool wear 3 Tool life monitoring provided FPG check by operator 6 108
Customer: Air & Fuel flow get affected 6
End User: Nil 1

2 ) Depth
ii) Ø29.30 +0.2
6 2

Nil
II) Depth oversize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list FPG check by operator 6 72
Customer:Air & Fuel flow get affected 6 Wrong tool offset 2 Program locked
End User: Nil 1
6 3
Down stream operation: Nil 1 Silicon % 2 Insp. Done at casting stage
Assy: NA 1 Build up edge 3 Tool life monitoring provided

l) M8x1 6H thread
SPG check by operator 6 108
damage
Customer: Filter not assemble 6 Wrong tool selection 2 Tool issue only as per tools list
Coolant level indicator available and
End User: Nil 1 Coolant not flow 2
machine stops on low level
Tool feed rate high 2 Program locked
6 3
Down stream operation: Nil 1 Drill dia undersize 3 Tool life monitoring provided
1) M8x1 6H Thread Assy: NA 1 Build up edge 3
specify in Opn.std
size
ll) M8x1 6H thread Go
( 1 places ) Customer:Filter not assemble 6 Coolant not flow 2 Flush coolant used to remove burr SPG check by operator 6 108
not answering
End User: Nil 1 Burr entrapment into tool holder 2 Coolant spray in tool holder
Wrong tool selection 2 Tool issue only as per tools list

Improper feed/Speed rate 2
program locked
6 3
20D) M8x1 6H Down stream operation: Nil 1 Build up edge 3
specify in Opn.std
Tapping ll) M8x1 6H thread
Assy: NA 1 Tool runout 3 Preventive check (before tool issue) SPG check by operator 6 108
NOGO answering
Customer: Affect the Filter Assembly 6 Burr entrapment into tool holder 2 Coolant spray in tool holder
End User: Nil 1 Spindle runout 2 preventive maintenance
6 3

2)Thread Depth l) Thread depth
Assy: Nil 1 Tool wear 3 Tool life monitoring provided SPG check by operator 6 108
Undersize
Customer: Affect the Filter Assembly
6
depth
End User: Nil 1
6 3
1 Resting pads not in same plane 2 Preventive maintanence
Nil
Assy: NA 1 Uneven clamping 2 Clamping pressure established
3) Position Position
Customer: Component getting disturbed while Ensure proper clamping of component Receiver Gauge checked by operator 6 108
0.2 wrt AB Out of spec 6 2
Cant able to assy the mating part machining against resting as per OS
Customer: Ensure proper adherance of tool life as
6 Position not ok 2
Cant able to assy the mating part per OS
End User: Nil Drill drag 3 Tool life monitoring provided
6 3
Nil
Assy: NA 1 Tool wear 2 Tool life monitoring provided

I) Groove ID oversize Gauge check by operator 6 108
Customer: Seal will not assemble 6 Spindle speed / Feed rate high 3
program locked
function
1)Groove ID Spindle runout 2 preventive maintenance
6 3
Nil
II) Groove ID undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Gauge check by operator 6 108
program locked
End User: Nil 1
6 3
Nil

I) Groove width
Gauge check by operator 6 108
oversize Established cutting parameters and
Customer: Seal will not assemble 6 Improper Spindle speed / Feed rate 3
program locked
function
2)3±0.2 Groove width End User: Nil
6 3
Nil
II) Groove width Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Gauge check by operator 6 108
undersize
program locked
End User: Nil 1
6 2
Nil

I) Groove depth
oversize Customer: Seal will not assemble
6 Wrong tool offset 2 Program locked
properly
2
Action Results
Occurrence
Detection
Occurrence
Severity
Responsibility
Detection
Class
Severity
RPN
RPN
completion date

function
3)Groove depth End User: Nil
6 2
Nil
II) Groove depth Assy: NA 1 Wrong tool offset 2 Program locked Gauge check by operator 6 72
undersize
Customer: Seal will not assemble
properly
End User: Nil 1
6 2
1 Built-up edge 2 Tool life monitoring provided
Nil
20E) ø13.50
Cutting parameter established during
Grooving Assy: NA 1 Spindle speed & feed 2
trials and program locked
I) Radius oversize Inspection by inspector as per QCPC 6 72
Customer: Seal will damaged 6 Wrong tool selection 2 Tool issue only as per tools list

6
function
4) Radius (4 places)
End User: Nil
R0.5
6 2
Nil
II) Radius undersize Assy: NA 1 Wrong tool offset 2 Program locked Inspection by inspector as per QCPC 6 72
Customer: Seal will damaged 6 Wrong tool selection 2 Tool issue only as per tools list
End User: Nil 1
6 2
Nil
I) Chamfer depth
Assy: NA 1 Wrong tool offset 2 Program locked Inspection by inspector as per QCPC 6 72
oversize
properly
6
function
5) Chamfer depth
6 2
Nil
II)Chamfer depth Assy: NA 1 Wrong tool offset 2 Program locked Inspection by inspector as per QCPC 6 72
undersize
Customer: Seal will not enter Into the
groove
End User: Nil 1
6 2
Nil
I) Chamfer angle more
6) Chamfer angle Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Inspection by inspector as per QCPC 6 72
or less
properly
6
function
6 3

7) Surface finish Assy: NA 1 Tool wear 2 Inspection by inspector as per QCPC 6 108
Customer:
Seal not seated properly
End User: Nil 1 Spindle speed / Feed rate high 3 Program locked
pressure
6 3
Down stream operation: Established cutting parameters and
1 Spindle speed / Feed rate high 3
Nil program locked
8) Concentricity 0.5 I) Concentricity out of Assy: NA 1 Tool wear 3 Tool life monitoring provided Concentricity gauge check by operator 6 108
wrt M8 spec
Customer: Fuel flow get affected 6 Clamping pressure more or less 2
pressure
End User: degradation of secondary Component getting disturbed while Pressure indicator to check the clamping
6 2
function machining pressure/ preventive Maintenance
6 3
Surface finish out of Assy: NA 1 Tool wear 2
specify in Opn.std Inspection by inspector as per QCPC 6 108
spec
Customer:
Improper sealing
1) Diameter Ø9 Pressure indicator to check the clamping

pressure
6 3
20F) Ø9 Drilling Nil
II) Drill dia undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Core plug gauge check by operator 6 108
program locked
End User: Nil 1
6 3

2) Depth (2-places)
l) depth Undersize Assy: Nil 1 Tool wear 3 Tool life monitoring provided CPG check by operator 6 108
Customer: Part cannot assemble 6
End User: Nil 1
6 3
Down stream operation: Nil 1 Build up edge 3 Tool life monitoring provided
Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list
l) M10x1 6H thread
damage Coolant level indicator available and
Customer: Filter not assemble 6 Coolant not flow 2
6 3
specify in Opn.std
size
not answering

program locked
20G) M10x1 6H 6 3
Thread milling
(3 places) Down stream operation: Nil 1 Build up edge 3
specify in Opn.std
ll) M10x1 6H thread
NOGO answering
6 3
3
Action Results
Occurrence
Detection
Occurrence
Severity
Responsibility
Detection
Class
Severity
RPN
RPN
completion date

Undersize
End User: Nil 1
6 3
3) Position 2nd setup operation cannot be done
Ø0.6 wrt JDA Position First off Inspection/ Interposition gauge
Assy: NA 1 Uneven clamping 3 preventive maintanence 6 108
Ø0.6 wrt FDA Out of spec check by operator
Ø0.6 wrt EAH Customer: Component getting disturbed while Ensure proper clamping of component
6 2
End User: Nil 1
6 3
11.10 + 0.1 Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list
intersection dia SPG check by operator 6 108
oversize Customer: O ring seat not properly 6 Spindle runout 2 Preventive maintanence
End User: Nil 1 Spindle speed & feed 2 Program locked

1) 11.10 + 0.1
intersection dia
6 3
Down stream operation: Nil 1 Form tool intersection dia undersize 3 Tool life monitoring provided
11.10 + 0.1
Establish tool change frequency and SPG check by operator 6 108
intersection dia Assy: NA 1 Build up edge 3
specify in Opn.std
undersize
Customer:O ring seat not properly 6 Wrong tool selection 2 Tool issue only as per tools list
End User: Nil 1 Improper feed/Speed rate 2
program locked
20H)M10 'O' ring
detail 6 3

Chamfer Depth & 1.60 +0.4,45° & 12°
Angle ,depth over size / Assy: Nil 1 Tool wear 3 Tool life monitoring provided SPG check by operator 6 108
Undersize
Customer: Part cannot assemble 6 Wrong tool selection 2 incomining tool inspection
End User: Nil 1
6 3
Surface finish specify in Opn.std Inspection by inspector as per QCPC 6 108
spec
Customer:
Improper sealing
pressure
Nil
Assy: NA 1 Spindle speed / Feed rate high 3
program locked
II) Drill dia Oversize Customer: Fuel flow get affected 6 Burr entrapment into tool holder 2 Coolant spray in tool holder
function
1) Drill ø3.00
6 3
Nil
II) Drill dia undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list plug gauge check by operator 6 108

Customer: Fuel flow get affected 6 Spindle speed / Feed rate high 3
program locked
End User: Nil 1
6 3

Inspection by inspector in Contour
20 I) Ø3 Drilling l) depth Undersize Assy: Nil 1 Tool wear 3 Tool life monitoring provided 6 108
Tracer
Customer: Fuel flow get affected 6
End User: Nil 1

2) Depth 48
6 2
Nil
II) Depth oversize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list 6 72
Tracer
Customer: Fuel flow get affected 6 Wrong tool offset 2 Program locked
End User: Nil 1
6 3
Nil
3) position X 1.25 Y Position
Assy: NA 1 Uneven clamping 3 preventive maintanence First off inspection 6 108
0.25 Out of spec
Customer: Component getting disturbed while Ensure proper clamping of component
6 2
Flow rate affected machining against resting as per OS
End User: Nil 1
6 3
Assy: Nil 1 Tool wear 3 Tool life monitoring provided Inspection by inspector through contour
I) Depth oversize tracer/ Also controlled by measuring 6 108
Customer: Fuel flow get affected 6 Ø5.1 depth
End User: Nil 6

1) Depth 34.3

6 2
Nil
Assy: NA 1 Tool wear 2 Tool life monitoring provided Inspection by inspector through contour
II) Depth undersize tracer/ Also controlled by measuring 6 72
Customer: Fuel flow get affected 1 Wrong tool selection 2 Tool issue only as per tools list Ø5.1 depth
6 3
Nil
program locked
I) Drill dia oversize plug gauge check by operator 6 108
Customer: Fuel flow get affected 6 Burr entrapment into tool holder 2 Coolant spray in tool holder

function
1) Diameter Ø3 Spindle runout 2 preventive maintenance
6 3
Nil
20 J) Ø5.1 pre
drill and Ø3 II) Drill dia undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list plug gauge check by operator 6 108
combination
program locked
End User: Nil 1
6 3
4
Action Results
Occurrence
Detection
Occurrence
Severity
Responsibility
Detection
Class
Severity
RPN
RPN
completion date
End User: Nil 1

2) Depth 30.6 ± 0.2
6 2
Nil
End User: Nil 1
6 2
Nil
Assy: NA 1 Clamping pressure more or less 2
3) Chamfer angle I) Chamfer angle more pressure
Inspection by inspector as per QCPC 6 72
118° or less
Customer: Improper assembly 6 Wrong tool selection 2 Tool issue only as per tools list

6
function
6 3
Down stream operation: Established cutting parameters and
Nil program locked

1) Concentricity 0.05 I) Concentricity out of
Pressure indicator to check the clamping First Off inspection 6 108
wrt Ø 3 spec Customer: Fuel flow get affected 6 Clamping pressure more or less 2
pressure
End User: degradation of secondary Component getting disturbed while Pressure indicator to check the clamping
6 2
function machining pressure/ preventive Maintenance
6 3
Nil
20 K) Ø5 .6 Established cutting parameters and
Reaming Assy: NA 1 Spindle speed / Feed rate high 3
program locked
I) Dia oversize Air plug gauge check by operator 6 108
Customer: NRV will not assemble
properly
End User: Nil 1 Wrong tool selection 2 Tool issue only as per tools list
1) Diameter
Ø5.6 ± 0.05
6 3
Nil
II) Dia undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Air plug gauge check by operator 6 108
Customer: NRV will not assemble 6 Spindle speed / Feed rate high 3
program locked
End User: Nil 1
OPERATION NO. #30 LEFT HAND SIDE & RIGHT HAND SIDE -2nd SETUP
6 3
Assy: NA 1 Wrong loading 3 Pokayoke provided 5 90
specify in Opn.std
1) Milling Height wrong tool offset 2 Program locked
23.57±0.25,
37.43±0.25, Established tool change frequency and
Build up edge 3
52.30±0.30 specify in Opn.std
6 3
assembly
6 3
Opn:30A) Milling
Flatness Assy: NA 1 Uneven clamping 3 preventive maintanence

2) Flatness 0.1 First off Inspection 6 108
Out of spec
assembly
6 3

3) Surface finish Assy: NA 1 insert wear 2 Inspection by inspector as per QCPC 6 108
Customer:
Leakage in assembly
End User: Nil 1 Buildup edge 3
specify in Opn.std
pressure
6 3
Nil
I) dia oversize Assy: NA 1 Spindle speed / Feed rate high 3 plug gauge check by operator 6 108
program locked
Customer: Solenoid valve will not
assemble properly

1) Diameter
Ø14.8 ±0.1 6 3
Nil
II) dia undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list plug gauge check by operator 6 108
Customer: Solenoid valve will not Established cutting parameters and
assemble program locked
End User: Nil 1
6 3
Customer: Fuel flow get affected 6 Wrong tool selection 2 Tool issue only as per tools list
End User: Nil 1

2) Depth 2.2 ± 0.1
6 2
Nil
End User: Nil 1
6 3
Nil
I) Core hole dia Established cutting parameters and
Assy: NA 1 Spindle speed / Feed rate high 3 Core plug gauge check by operator 6 108
oversize program locked
Customer: Play in valve assembly 6 Wrong tool selection 2 Tool issue only as per tools list

3) Pre drill diameter
Ø13 6 3
5
Action Results
Occurrence
Detection
Occurrence
Severity
Responsibility
Detection
Class
Severity
RPN
RPN
completion date

Nil
II) Core hole dia Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Core plug gauge check by operator 6 108
undersize
Customer: Valve will not assemble 6 Spindle speed / Feed rate high 3
program locked
End User: Nil 1
1 3
Improper finish
30B) Ø14.8
counterbore , Ø13 Established cutting parameters and
pre drill and Ø5.4 program locked Controlled by Ø5.9 Air gauge check by
I) drill dia oversize 6 18
drill operator
Customer: Nil 1 Wrong tool selection 2 Tool issue only as per tools list
(2 - places)
4) Pre drill diameter
Ø5.4
6 3
Improper finish
Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Controlled by Ø5.9 Air gauge check by
II) drill dia undersize 6 108
operator
Customer: Nil 1 Spindle speed / Feed rate high 3
program locked
End User: Nil 1
6 3
Customer: Air & Fuel flow get affected 6
End User: Nil 1

5) Depth
ii) Ø9.3 +0.1 6 2
Nil
End User: Nil 1
6 3
l) depth Undersize Assy: Nil 1 Tool wear 3 Tool life monitoring provided Inspection by inspector as per QCPC 6 108
Customer: Valve will not assemble

6
properly
End User: Nil 1
6) Chamfer Depth 0.5
6 2
Nil
II) Depth oversize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Inspection by inspector as per QCPC 6 72
Customer: Valve will not assemble
properly
End User: Nil 1
6 2
Nil
7) Chamfer angle I) Chamfer angle more Pressure indicator to check the clamping
Assy: NA 1 Clamping pressure more or less 2 Inspection by inspector as per QCPC 6 72
45° or less pressure
Customer: Improper assembly 6 Wrong tool selection 2 Tool issue only as per tools list

6
function
6 3
Nil
I) Dia oversize Assy: NA 1 Spindle speed / Feed rate high 3 Air plug gauge check by operator 6 108
program locked
Customer: Assembly fitment will be
losse

1) Diameter
Ø6 (-0.1/0.07) 6 3
Nil
Customer: Assembly canot be carried Established cutting parameters and
out program locked
End User: Nil 1
6 3

l) depth Undersize FPG check by operator 6 108
30C ) Ø5.915 Assy: Nil 1 Tool wear 3 Tool life monitoring provided
Reaming
Customer: Affect the assembly 6
End User: Nil 1
2) Depth
Ø13.30 ±0.05 6 2

Nil
II) Depth oversize FPG check by operator 6 72
Customer: Affect the assembly 6 Wrong tool offset 2 Program locked
End User: Nil 1
6 3
Assy: NA 1 Tool wear 2
Surface finish out of specify in Opn.std
3) Surface finish Inspection by inspector as per QCPC
spec Customer:
Improper sealing

pressure
6 3
l) M14x1 6H thread
First off inspection 6 108
Customer: 100% part scrapped 6 Coolant not flow 2
End User: Nil 1 Clamping pressure more or less 2
pressure
6 3
1) M14x1 6H Thread
size Assy: NA 1 Build up edge 3
ll) M14x1 6H thread Go specify in Opn.std
( 2 places ) SPG check by operator 6 108
not answering
Customer: Air & Fuel SOV not assemble 6 Coolant not flow 2 Flush coolant used to remove burr

program locked
6
Action Results
Occurrence
Detection
Occurrence
Severity
Responsibility
Detection
Class
Severity
RPN
RPN
completion date
6 3
30D) M14 X 1 Establish tool change frequency and

Down stream operation: Nil 1 Build up edge 3
Thread milling specify in Opn.std
ll) M14x1 6H thread
NOGO answering
Customer: Air & Fuel SOV not assemble 6 Spindle runout 2 preventive maintenance
End User: Nil 1
6 3

Undersize
End User: Nil 1
6 3
Down stream operation: Nil 1 Resting pads not in same plane 2 Preventive maintanence
Assy: NA 1 Uneven clamping 3 preventive maintanence Receiver Gauge inspection by operator 5 90
0.6 wrt ABH Out of spec
6 2
End User: Nil 1
6 3
Nil
program locked
I) Groove ID oversize Gauge check by operator 6 108
Customer: Seal will not assemble 6 Burr entrapment into tool holder 2 Coolant spray in tool holder

function
1)Groove ID
19.8 ± 0.1
6 3
Nil
II) Groove ID undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Gauge check by operator 6 108
program locked
End User: Nil 1
6 3
Nil
Assy: NA 1 Improper Spindle speed / Feed rate 3
I) Groove width program locked
oversize
Customer: Seal will not assemble 6 Wrong tool selection 2 Tool issue only as per tools list
End User: Nil 6
2)Groove width
6 3
Nil
II) Groove width Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Gauge check by operator 6 108
undersize
program locked
End User: Nil 1
6 2
Nil
30E) Grooving
I) Groove depth
Assy: NA 1 Wrong tool offset 2 Program locked Gauge check by operator 6 72
oversize
properly
6
4)Groove depth function
1.2 - 0.15 6 2
Nil
II) Groove depth Assy: NA 1 Wrong tool offset 2 Program locked Gauge check by operator 6 72
undersize
properly
End User: Nil 1
6 2
1
Nil
Built-up edge 2 Tool life monitoring provided
I) Radius oversize Assy: NA 1 Inspection by inspector as per QCPC 6 72

Customer: Seal will not assemble 6 Spindle speed & feed 2
5) Radius (4 places) function
R0.2 6 2
Nil
II) Radius undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Inspection by inspector as per QCPC 6 72
Customer: Seal will Damage to assemble 6
End User: Nil 1
6 3

Customer:Nil 6 Less Coolant flow 2 Failsafe alarm available in machine
pressure
6 3
Thread cannot be formed
program locked
running
function
30F) Ø3.3 drilling 1) Ø3.3 drill Spindle runout 2 preventive maintenance
6 3
Nil
program locked
End User: Nil 1
6 3
l) M8x1 6H thread
First off inspection 6 108
Customer: 100% part scrapped 7 Coolant not flow 2
7
Action Results
Occurrence
Detection
Occurrence
Severity
Responsibility
Detection
Class
Severity
RPN
RPN
completion date
6 3
Assy: NA 1 Build up edge 3
1) M4*0.7 Thread size specify in Opn.std
( 2 places ) ll) M4x0.7 6H thread Go
Customer: Screw not assemble 6 Coolant not flow 2 Flush coolant used to remove burr SPG check by operator 6 108
not answering
30G) M4*0.7
Tapping Wrong tool selection 2 Tool issue only as per tools list
(4 places)
program locked
6 3
specify in Opn.std
ll) M4x0.7 6H thread
NOGO answering
Customer: Screw will shear due to cyclic
load
6 3 5 90
Down stream operation: Nil 1 Wrong tool offset 2 Program locked 8 96

2)Thread Depth
l) depth not through Assy: Nil 1 Tool wear 3 Tool life monitoring provided SPG check by operator 6 108
Through
End User: Nil 1
6 3

program locked
I) Drill dia oversize Plug gauge check by operator 6 108
Customer: Part cannot assemble 6 Burr entrapment into tool holder 2 Coolant spray in tool holder

function
1) Ø3.1 drill Spindle runout 2 preventive maintenance
6 3
Nil
II) Drill dia undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Plug gauge check by operator 6 108
Customer: Part cannot assemble 6 Spindle speed / Feed rate high 3
program locked
30H) Ø3.1 drilling End User: Nil 1
6 3
Down stream operation:Nil 1 Wrong tool offset 2 Program locked
End User: Nil 1

2) Depth 2.2 ± 0.1
6 3
Nil
Customer: Part cannot assemble 6 Wrong tool offset 2 Program locked
End User: Nil 1
6 3
ø8.0 size not atcheived
30I ) Ø4/7.40 1) Diameter I) Dia oversize / Under program locked
Air plug gauge check by operator 6 108
Drilling Ø4/7.40 size Customer: Assembly fitment will be
losse
6 3
Nil
program locked
Customer: Assembly fitment will be
losse
1) Diameter
Ø8 (-0.1/0.07)
6 3
Nil
II) Dia undersize Air plug gauge check by operator 6 108
30I) Ø8 Reaming Customer: Assembly canot be carried
out
End User: Nil 6 Spindle speed / Feed rate high 3
program locked
6 3

Customer:
Improper sealing
pressure
Nil
program locked
II) Drill dia Oversize Customer: Fuel flow get affected 6 Burr entrapment into tool holder 2 Coolant spray in tool holder
function
1) Drill ø3.00
6 3
Nil

program locked
End User: Nil 1
6 3

30J) Ø3 Drilling l) depth Undersize Assy: Nil 1 Tool wear 3 Tool life monitoring provided 6 108
Tracer
End User: Nil 1

2) Depth 48
6 2
Nil
II) Depth oversize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list 6 72
Tracer
8
Action Results
Occurrence
Detection
Occurrence
Severity
Responsibility
Detection
Class
Severity
RPN
RPN
completion date
End User: Nil 1
6 3
Nil
3) position X 1.25 Y Position
Assy: NA 1 Uneven clamping 3 preventive maintanence First off inspection 6 108
0.25 Out of spec
6 2
Flow rate affected machining against resting as per OS
End User: Nil 1
6 3
Nil
program locked

function
6 3
Nil
30K) Ø4 Drilling
program locked
End User: Nil 1
6 3

2) Depth Inspection by inspector in Contour
l) depth not through Assy: Nil 1 Tool wear 3 Tool life monitoring provided 6 108
through Tracer
End User: Nil 1
6 3
Nil
program locked
Customer: Air flow get affected 6 Burr entrapment into tool holder 2 Coolant spray in tool holder

function
6 3
Nil
Customer: Air flow get affected 6 Spindle speed / Feed rate high 3
program locked
30L ) Ø5 Drilling End User: Nil 1
6 3
Customer: Air flow get affected 6
End User: Nil 1

2) Depth (2-places)
6 2
Nil
II) Depth oversize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Core plug gauge check by operator 6 72
Customer: Air flow get affected 6 Wrong tool offset 2 Program locked
End User: Nil 1
6 3
Nil
program locked

function
6 3
Nil
program locked
6
function
30M) Ø7.5 Drilling
6 2
Nil
Assy: NA 1 Wrong tool offset 2 Program locked

I) Depth oversize Gauge check by operator 6 72

6
function
2)Depth
20.8
6 2
Nil
II) Depth undersize Assy: NA 1 Wrong tool offset 2 Program locked Gauge check by operator 6 72

1
function
6 3
Nil
program locked 6 108
I) Drill dia oversize Core plug gauge check by operator
Customer: Play in thread assembly 6 Burr entrapment into tool holder 2 Coolant spray in tool holder
function
6 3
Nil

program locked
End User: Nil 1
6 3
Down stream operation: Thread cannot
be formed properly
l) Depth Undersize Assy: Nil 1 Tool wear 3 Tool life monitoring provided Core plug gauge check by operator 6 108
Customer: Valve cannot be assembled 6
9
Action Results
Occurrence
Detection
Occurrence
Severity
Responsibility
Detection
Class
Severity
RPN
RPN
completion date
End User: Nil 1

2) Depth 14
6 2
30N) ø12.50 1 Tool wear 2 Tool life monitoring provided
Nil
Drilling and Ø25
cutter spot facing II) Depth oversize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Core plug gauge check by operator 6 72
End User: Nil 1
6 3
Flatness
3) Flatness 0.1 Assy: NA 1 Uneven clamping 3 preventive maintanence First off Inspection 6 108
Out of spec
assembly
6 3
Down stream operation:Nil 1 Wrong tool offset 2 Program locked
l) depth Undersize Assy: Nil 1 Tool wear 3 Tool life monitoring provided Receiver gauge check by operator 6 108
Customer: Valve blocks the flow 6
End User: Nil 1

4) Depth 36.07 ± 0.25
6 2
Nil
II) Depth oversize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Receiver gauge check by operator 6 72
End User: Nil 1
6 3
l) M14x1.5 6H thread
6 3
1) M14x1 .5 6H Assy: NA 1 Build up edge 3
specify in Opn.std
Thread size
Go not answering

program locked
6 3
30O) M14 X 1.5
Thread milling Establish tool change frequency and
specify in Opn.std
NOGO answering
6 3

Undersize
End User: Nil 1
6 3
2nd setup operation cannot be done
Assy: NA 1 Uneven clamping 3 preventive maintanence Receiver Gauge inspection by operator 5 90
0.6 wrt GBA Out of spec
6 2
End User: Nil 1
6 3
15.80 + 0.1 intersection
dia oversize
Customer: O ring seat not properly 6 Spindle runout 2 Preventive maintanence

1) 15.80 + 0.1
intersection dia
6 3
30P) M14 O ring
detail 15.80 + 0.1 intersection Establish tool change frequency and
Assy: NA 1 Build up edge 3 SPG check by operator 6 108
dia undersize specify in Opn.std
program locked
6 3

Chamfer Depth & 2.40 +0.4,45° & 15°±1°
Angle depth over size / Assy: Nil 1 Tool wear 3 Tool life monitoring provided SPG check by operator 6 108
Undersize
End User: Nil 1
6 3
spec
Customer:
Improper sealing
1) Diameter Ø9 Pressure indicator to check the clamping

pressure
6 3
30Q) Ø9 Drilling Nil
program locked
End User: Nil 1
6 3

2) Depth (2-places)
End User: Nil 1
6 3
10
Action Results
Occurrence
Detection
Occurrence
Severity
Responsibility
Detection
Class
Severity
RPN
RPN
completion date
l) M10x1 6H thread
6 3
specify in Opn.std
size
not answering

program locked
30R) M10x1 6H 6 3
Thread milling
(3 places) Down stream operation: Nil 1 Build up edge 3
specify in Opn.std
ll) M10x1 6H thread
NOGO answering
6 3

Undersize
End User: Nil 1
6 3
3) Position 2nd setup operation cannot be done
Ø0.6 wrt JDA Position First off Inspection/ Interposition gauge
Assy: NA 1 Uneven clamping 3 preventive maintanence 6 108
Ø0.6 wrt FDA Out of spec check by operator
Ø0.6 wrt EAH Customer: Component getting disturbed while Ensure proper clamping of component
6 2
End User: Nil 1
6 3
Down stream operation: Nil 1 Coolant concentration 2
Before coolant top up, check coolant
spec Customer:
Improper sealing
1) Diameter Ø6.0 Clamping pressure more or less 2
pressure
6 3
30S) Ø6.0Drilling Nil
program locked
End User: Nil 1
6 3

2) Depth (Through)
End User: Nil 1
6 3
11.10 + 0.1 Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list
intersection dia SPG check by operator 6 108
oversize Customer: O ring seat not properly 6 Spindle runout 2 Preventive maintanence

1) 11.10 + 0.1
intersection dia
6 3
11.10 + 0.1
Establish tool change frequency and SPG check by operator 6 108
intersection dia Assy: NA 1 Build up edge 3
specify in Opn.std
undersize
program locked
30U)M10 'O' ring
detail 6 3

Chamfer Depth & 1.60 +0.4,45° & 12°
Angle ,depth over size / Assy: Nil 1 Tool wear 3 Tool life monitoring provided SPG check by operator 6 108
Undersize
End User: Nil 1
6 3
Surface finish specify in Opn.std Inspection by inspector as per QCPC 6 108
spec
Customer:
Improper sealing
pressure
30V) Side Milling 6 3

Assy: NA 1 Wrong loading 3 Pokayoke provided 6 108
specify in Opn.std
wrong tool offset 2 Program locked
1) Milling Distance
9.0+0.1/-.3 Established tool change frequency and
Build up edge 3
specify in Opn.std
6 3
assembly
1 3
Nil
program locked Inspection by inspector as per control
I) spot face dia oversize 6 18
plan
Customer: Nil 1 Burr entrapment into tool holder 2 Coolant spray in tool holder
1) DiameterØ16 Spindle runout 2 preventive maintenance
6 3
Nil
30W) Spot facing
11
Action Results
Occurrence
Detection
Occurrence
Severity
Responsibility
Detection
Class
Severity
RPN
RPN
completion date
30W) Spot facing

II) spot face dia Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Inspection by inspector as per control
6 108
undersize plan
Customer: Bolt will not assemble 6 Spindle speed / Feed rate high 3
program locked
End User: Nil 1
6 3
Down stream operation: Nil 1 Coolant concentration 2 Program locked
2) Flatness l) Flatness out of Assy: Nil 1 Tool wear 2 Tool life monitoring provided First off inspection 6 108
specification
Customer: Part cannot assemble 6 Spindle speed / Feed rate high 3
program locked
End User: Nil 1
6 2
Nil

I) Dia oversize Inspection by inspector as per QCPC 6 72
properly
6
function
Tool dia
11.50 & ø25.0
6 2
Nil
II) Dia undersize Assy: NA 1 Wrong tool offset 2 Program locked Inspection by inspector as per QCPC 6 72
groove
End User: Nil 1

30X) Ø11.5 drill
and Ø25 spot face
6 2
Nil

I) Depth oversize Receiver Gauge check by operator 6 72
Customer: Flow get affected due to
improper sealing
6
function
Height 64.1 ± 0.3
6 2
Nil
II) Depth undersize Assy: NA 1 Wrong tool offset 2 Program locked Receiver Gauge check by operator 6 72
assembly
End User: Nil 1
6 3

Customer:
Improper Sealing
pressure
6 3
Nil
30Y) Ø12 H9 Established cutting parameters and
Reaming Assy: NA 1 Spindle speed / Feed rate high 3
program locked
Customer: Outlet valve will not assembe 6 Burr entrapment into tool holder 2 Coolant spray in tool holder
1) Diameter
Ø12 H9
6 3
Nil
Customer: Outlet valve will not assembe 6 Spindle speed / Feed rate high 3
program locked
End User: Nil 1
6 3
Nil
program locked
I) Outer dia oversize Gap gauge check by operator 6 108
running
1) Outer ø 20 ± 0.1 Spindle runout 2 preventive maintenance
6 3
Nil
II) Outer dia undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Gap gauge check by operator 6 108
Customer: Leak during assembly 6 Spindle speed / Feed rate high 3
program locked
End User: Nil 1
6 3
Nil
program locked
I) Outer dia oversize Gap gauge check by operator 6 108
Customer: Valve will not assemble 6 Burr entrapment into tool holder 2 Coolant spray in tool holder
2) Dia 16 - 0.2 Spindle runout 2 preventive maintenance
6 3
Nil
II) Outer dia undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Gap gauge check by operator 6 108
Customer: Leak during assembly 6 Spindle speed / Feed rate high 3
program locked
End User: Nil 1
6 3
Nil
Assy: NA 1 Improper Spindle speed / Feed rate 3
program locked
I) width oversize Thickness Gauge check by operator 6 108
Customer: Outlet valve will not assembe 6 Burr entrapment into tool holder 2 Coolant spray in tool holder
3) width
6 3
Nil
II) width undersize Assy: NA 1 Wrong tool selection 2 Tool issue only as per tools list Thickness Gauge check by operator 6 108
12
Action Results
Occurrence
Detection
Occurrence
Severity
Responsibility
Detection
Class
Severity
RPN
RPN
completion date

Customer: Play in Outlet valve assembly 6 Improper Spindle speed / Feed rate 3
program locked
30Z) OD Forming 1
function
6 2
1
Nil
Built-up edge 2 Tool life monitoring provided
Assy: NA 1
I) Radius oversize Inspection by inspector as per QCPC 6 72
Customer: Seal will not assemble 6 Spindle speed & feed 2
function
4) Radius (4 places)
R0.5 - 0.15
6 2
1
Nil
Tool wear 2 Tool life monitoring provided
II) Radius undersize Assy: NA 1 Inspection by inspector as per QCPC 6 72
Customer: Seal will not assemble 6

End User: Nil 1
6 2
Nil
5) Depth Assy: NA 1 Wrong tool offset 2 Program locked
II) Depth undersize Gap Gauge check by operator 6 72
8 Min
properly
End User: Nil 1
6 2
Nil

I) Chamfer depth
Inspection by inspector as per QCPC 6 72
oversize Customer: Seal will not assemble
properly
6
function
6) Chamfer depth
i) 0.8
6 2
Nil
II)Chamfer depth Assy: NA 1 Wrong tool offset 2 Program locked Inspection by inspector as per QCPC 6 72
undersize
groove
End User: Nil 1
6 2
Nil
7) Chamfer angle I) Chamfer angle more Pressure indicator to check the clamping
Assy: NA 1 Clamping pressure more or less 2 Inspection by inspector as per QCPC 6 72
ii)45° or less pressure
properly
6
function
Functional Characteristic
7 3 Firstoff inspection 5 105
Down stream operation: Nil 1 Damage due to deburring 3 Trained Operator 200% Visual inspection 7 147
Handling damage while loading the Single setup and provided proper material
No damage Damage Assy: Nil 1 2 100% Visual inspection 8 112
machine handling in machine
Customer :
7 Clamping pressure high 2 Preventive maintenance Process audit 8 112
100% parts may have to be scrapped
End User: Nil 1
1 Clamping pressure less/high 2 Preventive maintenance Process audit 8 112
Nil
No Tool mark Tool mark Customer : Establish tool change frequency and
7 Tool wear 2 200% Visual inspection 7 98
100% parts may have to be scrapped specify in Opn.std
Assy : Establish tool change frequency and
1 Build up edge 2 200% Visual inspection 7 98
NA specify in Opn.std
End user :
1 Jack supporting pressure low/high 2 None Preventive check and process audits 7 98
Nil
30Y) Functional
Characteristic Down stream operation :
100% parts may have to be reworked 6 Coolant concentration not ok 3 None Checked once per day 6 108
offline
Free from Loose Customer :
Loose Burrs Optimize coolant flow during machining
Burrs 100% of production run may have to be 6 Coolant not flow 2 Process audit 7 84
scrapped. trials
Assy :
1
NA
End user :
1
Nil
6 2
Nil 1 Tool wear 2 Tool life Monitoring established
Ø1.75 min shoul pass Customer :

Ø1.75 did not pass 100% Gauge check by final inspector 6 72
through Ø3 drill Fuel flow get affected 6 Wrong Tool offset 2 Program Locked
Assy : Washing process developed with high

1 Imp solution blocked 2
NA pressure to remove all blockages
End user :
1
Nil
OPERATION NO. #40 Deburring
As per established Air pressure indicated Monitoring the right pressure thru pressure
Down stream operation: Nil 1 Insufficient Air pressure 2 6 72
in OS gauge
Air cleaning of parts Free from presence of
40) Deburring & Customer:
to be free from burrs or coolant 6
Air cleaning a) Fails at performance testing Untrained operator 2 Trained operator Process audit 7 84
sharpe edge, burrs particles inside the
process b) Leads to White rust formation
and coolant particles component
Air pressure gauge level unknown to
Assy: Nil 1 2 Established air pressure used in line Process audit 7 84
operator
End User: Nil 1
OPERATION NO. #50 Washing
6 3
Down stream operation: Nil 1 Nozzle tip blockage 2 Preventive maintanence
Washing time fixed using sensor as per

Assy: Nil 1 Washing time less 2
customer requirement
I) Cleanliness not ok / Customer:

Firstoff inspection 6 108
Presence of loose burrs a) Affects part performance after Preventive check using burr removal and
6 Nozzle not fixed for that hole 2
assembling the part grease test analysis
b) Inconvenience while handling the part
PLC controller available /
End User: Nil 1 Water pressure low 2 Monitoring the water pressure gauge
every shift beginning by operator
Preventive maintanence/ Process Audit in
Filter not cleaned 3
PH monitoring check sheet
6 3
As per the given Down stream operation: Nil 1 Contaminated water (PH) 3 Water change frequency monitoring
50) Washing Cleanliness standard
16599 Firstoff inspection 6 108
ii)Contamination due to Assy: Nil 1 Oil skimmer not functioning 2 Preventive maintanence
Oil/ Dirt/ Coolant
Customer:
a) Affects part performanc after 6 Water not good 3 Water change frequency monitoring
assembling the part
End User: Nil 1
5 3
13
Action Results
Occurrence
Detection
Occurrence
Severity
Responsibility
Detection
Class
Severity
RPN
RPN
completion date
Down stream operation: Nil 1 Mixer of coolant level high 3 None
Assy: Nil 1 Water temperature low 3 Preventive maintanence 100% check for white rust by final
iii) White rust 6 90
Customer: inspector
5 Contaminated water (PH) 3 Water change frequency monitoring
a)Poor outside side look of the part
Water change frequency not
End User: Nil 1 3 None
monitoring
Component kept at washing station Timing sensor available/ Heater available
2
for long to remove moisture
OPERATION NO. #60 Impregnation
6 3
Down stream operation: Leak due to
1 Resin concentration 3 As per established in OS
cavity unfill
Free from IMP Customer:
solution blockage / IMP solution blockage / a) Leak may occur 6 Untrained operator 3 Trained operator 100% checked by operator,
60) Impregnation Unwash / IMP Unwash / IMP b) Leads to White rust formation 100% IMP punch verified by final 6 108
concentration not concentration not good Clear identification to be followed inspector
good a) Punch mark provided on Ok parts by
Assy: Nil 1 Leak testing operation missing 3
machine before declamping
b) 200% Visual inspection
End User: Nil 1 Impregnation missing 3 Nil
OPERATION NO. #70 Leak testing
6 3
Single piece flow followup

a) Punch mark provided on Ok parts by
Down stream operation: Nil 1 Leak testing operation missing 2
machine before declamping
b) 200% Visual inspection
Parts failed in leak test getting mixed

Assy: Nil 1 2 Separate Red bin provided for Not ok part
up with good parts
Customer:
Leak test rig designed as per our
Component fails in leak test during 6 Not feasible to check leak 2
feasibility commitment
assembly, A portion of parts may scrap
Sensor available, if pressure get down
Leak testing pressure lesser than the from fixed minimum outlet pressure, 100% checked by operator, 100% Leak
70) Leak testing Free from Leak Leak at customer end End User: Nil 1 2 6 108
specification of 7 bar alarm will appear punch verified by final inspector
Untrained operator 2 Trained and specific person only alloted
Clamping not working 3 Preventive maintanence
Less time for leak testing 2 It controlled by PLC
Seal not as per customer seal 3 Aware of customer sealing
Identification for IMP is on part, the part

After IMP leak test not done 2
will get re-leak
Monitor seal life and mention seal
Seal getting damage 2
changing frequency in OS
OPERATION NO. #80 Washing
6 3
Down stream operation: Nil 1 Nozzle tip blockage 2 Preventive maintanence
Washing time fixed using sensor as per

Assy: Nil 1 Washing time less 2
customer requirement
I) Cleanliness not ok / Customer:

Firstoff inspection 6 108
Presence of loose burrs a) Affects part performance after Preventive check using burr removal and
6 Nozzle not fixed for that hole 2
assembling the part grease test analysis
b) Inconvenience while handling the part
PLC controller available /
End User: Nil 1 Water pressure low 2 Monitoring the water pressure gauge
every shift beginning by operator
Preventive maintanence/ Process Audit in
Filter not cleaned 3
PH monitoring check sheet
6 3
As per the given Down stream operation: Nil 1 Contaminated water (PH) 3 Water change frequency monitoring
80) Washing Cleanliness standard
16599 Firstoff inspection 6 108
ii)Contamination due to Assy: Nil 1 Oil skimmer not functioning 2 Preventive maintanence
Oil/ Dirt/ Coolant
Customer:
a) Affects part performanc after 6 Water not good 3 Water change frequency monitoring
assembling the part
End User: Nil 1
5 3
Down stream operation: Nil 1 Mixer of coolant level high 3 None
Assy: Nil 1 Water temperature low 3 Preventive maintanence 100% check for white rust by final
iii) White rust 6 90
Customer: inspector
5 Contaminated water (PH) 3 Water change frequency monitoring
a)Poor outside side look of the part
Water change frequency not
End User: Nil 1 3 None
monitoring
Component kept at washing station Timing sensor available/ Heater available
2
for long to remove moisture
OPERATION NO. #90 Air Cleaning
5 3
5 Air cleaning Pressure 3 Preventive maintanence
Nil
Heater time established, Timing sensor
90) Air Cleaning Air cleaning Free from moisture Assy : NA 1 Cleaning temperature 2 100% checked by final inspection 6 90
available
Customer : Nil 1
End User : Nil 1
OPERATION NO. #100 Drying
5 3
100% of production run may have to be 5 Heater Temperature not in spec 3 Preventive maintanence
reworked in station.
100) Drying Drying Free from moisture Heater time established, Timing sensor 100% checked by final inspection 6 90
Assy : NA 1 Heater Cycle time less 2
available
Customer : Nil 1
End User : Nil 1
OPERATION NO. #110 Final Inspection
5 3
Operator not aware of identifying the a) OJT for final inspectors

Parts free from visual Down stream operation: Nil 1 3
visual defects b) Operator traceability code on the part
defects like Sharp 6 90
edges, damages, tool No knowledge of customer a) Every complaint One point lesson 100% check by final inspection
110) Final Free from visual Assy: Nil 1 2
mark / chattering complaints displayed at final inspection station
Inspection defects
mark and blow holes, Customer:
5
damage and Cold a) Fails at performance testing
shut
End User: Nil 1
OPERATION NO. #120 Packing
5 3
1) Parts free from
1) No damage while Operator not aware of identifying the a) OJT for final inspectors
visual defects like Down stream operation: Nil 1 3
transporting visual defects b) Operator traceability code on the part
damages, white rust
2)Parts getting mixed 100% check by final inspection 6 90
120) Packing 2) Free from part mixup Assy: Nil 1 Part getting mixed up 3 Only one variant running at that time
up
Customer:
5
a) Fails performance testing
End User: Nil 1
Special Characteristics Symbol: Critical Characteristics Major Characteristics
*Priorites for determining recommended action: 1) Severity ≥ 8 ; (OR) 2) Detection > 6 ; (OR) 3) RPN ≥ 125
F/PED/04-M; Rev No.1; Dated: 25.02.2010
14

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Action Results

OPERATION NO. #10 Receive casting

During storage / Method of storage 3 Dedicated trolley with separator

Down stream operation :

2) No white rust White rust Assy : 200% checked by inspector 6 108

Down stream operation :

Down stream operation :

15 Shift Code Assy :

Down stream operation :

Location & orientation Assy :

Flatness Assy: NA 1 Uneven clamping 3 preventive maintanence

End User: Nil 1 Wrong tool offset 2 Program locked

Coolant secondary filter provided &

End User: Nil 1

Down stream operation: Establish tool change frequency and

Component getting disturbed while Ensure proper clamping of component

Established cutting parameters and

End User: Nil 1

Assy: NA 1 No machining Allowance 2 Insp. Done at casting stage

Spindle runout 2 preventive maintenance

Down stream operation:

Established cutting parameters and

End User: Nil 1

End User: Nil 1

Down stream operation: Nil 1 Wrong tool offset 2 Program locked

Customer: Air & Fuel flow get affected 6

End User: Nil 1

Down stream operation:

End User: Nil 1

Down stream operation: Nil 1 Silicon % 2 Insp. Done at casting stage

Assy: NA 1 Build up edge 3 Tool life monitoring provided

Wrong tool selection 2 Tool issue only as per tools list

End User: Nil 1 Spindle runout 2 preventive maintenance

Down stream operation: Nil 1 Wrong tool offset 2 Program locked

End User: Nil Drill drag 3 Tool life monitoring provided

Assy: NA 1 Tool wear 2 Tool life monitoring provided

End User: Nil 1

Assy: NA 1 Build up edge 2 Tool life monitoring provided

End User: Nil 1

Assy: NA 1 Build up edge 2 Tool life monitoring provided

End User: degradation of secondary

End User: Nil 1

End User: degradation of secondary

End User: Nil 1

End User: Nil 1

Coolant secondary filter provided &

1) Diameter Ø9 Pressure indicator to check the clamping

End User: Nil 1

Down stream operation: Nil 1 Wrong tool offset 2 Program locked

Customer: Part cannot assemble 6

End User: Nil 1

Tool feed rate high 2 Program locked

Wrong tool selection 2 Tool issue only as per tools list

End User: Nil 1 Spindle runout 2 preventive maintenance

Down stream operation: Nil 1 Wrong tool offset 2 Program locked

End User: Nil 1

End User: Nil 1 Spindle speed & feed 2 Program locked

Down stream operation: Nil 1 Wrong tool offset 2 Program locked