Documen F/NPD/06

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PFMEA) Revisio

04
n No.
Product : Automotive Inner Buty Process : Final Compound Mixing ……. Process-03 Revision 29.01.2021
Customer : All Customer Process Responsibility : Technical / QA Respo
Page
nsibilit 1OF 1
Core team : RD/DKS/SNS/AP Process Owner : Production Head
y&
Sub Target Action Results

DETECT
Potential

OCCUR
CLASS
Recommen
Process Potential Potential Effects(s) Current Process Control Current Process Control Compl

RPN
SEV
Requirement cause(s) ded
Step/ Failure Mode of Failure Mechanism(s (Prevention) (Detection) etion
1-Every batch/shift by Action(s) Action SDO R
Function ) of Failures
prod.supervisor
S.G. of 1-Standardisation of m/c
Weighing 2-Two
Compound out of### Scale with weights-start of shift
2 times/comp/shift by 5 50 -
Spec. 2-Calibration of m/c-once
Faulty Prod.supervisor
(A Portion of the in month
production run may have 3-One check/day by
3.1 / Correct to be reworked offline### Un skilled Training Plan &
QA supervisor
Weighing Weighed 2 On Job Training 1-Every batch/shift by 1 10
(Next and accepted) Man power Effectiveness
prod.supervisor
Impro Process Green Tube Wt
of Master Ingradient
1-Standardisation of m/c
Compoun s as per
per ) Variation Weighing 2-Two
d& Compoun with weights-start of shift
Weigh Our ###
( A Portion of the Scale 2 times/comp/shift by 5 50
Chemical d Receipy 2-Calibration of m/c-once
ment End production run Faulty Prod.supervisor
s as per in month
Specificati Specificati may have to be 3-One check/day by
Un skilled Training Plan &
QA supervisor
on . on . reworked offline### Man power 2 On Job Training
Effectiveness
1 10
and accepted.)
Daily QA Checksheet
- ### - 2 - 5 50
( PFM)
Custom
er End NO Effect ###- - 1 - N/A 1 1
1-Sequence of Mixing as 1-Visual / Mixing
1-Mixing 8 72
per F/QAD/24(FINAL Operator
sequence- 1-Visual / Mixing
### 3 COMP.SPEC.) 2-One Check / Day
Out of Spec
2-Work execution as per Operator
by QA Supervisor as
, 2-
WI/TECH/03 perTwoTimes
F/QAD/11/Comp.. /
2 12
1-Auto Cut by Digital Shift/ Prod.
2-Mixing
Poor Dispersion Timer Supervisor in
### Time-Out of 2 1-Visual / Mixing
(A Portion of the 2-Work execution as per F/PRD/11(FINAL
Spec , Operator
(Next production run WI/TECH/03
1-Air Pressure set & Cutt COPM. MIXING)
Process may have to be
2-Two times /
Homogen off at Main Compressure . 3-One Check / Day 2 6
3.2 / Unmix ) reworked in- 3-Air Comp
by QA /Shift in
Supervisor as
eous 2-Air Pressure as per
Mixing of
Mixing of
ed Our station before it is### Pressure of F/PRD/11(FINAL
per F/QAD/11 .
Batch in Comp End 1 F/QAD/24(FINAL 1-Visual / Mixing
Compoun processed) RAM- COPM. MIXING) by
Kneader ound 1-PLC Controlled Digital Operator
COMP.SPEC.)
d Incorrect Prod. Supervisor
Display
3-Work execution as per 2-Two times /
3-One Check / Day 2 6
2-Dump
WI/TECH/03Temp Comp /Shift in
4-Dump by QA Supervisor as
maintained as per F/PRD/11(FINAL
### Temp-Out 1 per F/QAD/11 .
F/QAD/24(FINAL COPM. MIXING) by
of Spec.
COMP.SPEC.) Prod. Supervisor
2-Work execution as per 3-One DailyCheck / Day
QA Check 8 24
- ###- - 1 WI/TECH/03- by QA Supervisor
Sheet (PFM) as
Custom per F/QAD/11 .
er End
NO Effect ###- - 1 - N/A 1 1
1-Number of Cuts as per 1-Visual / Mixing 8 72
Number of F/QAD/24(FINAL Operator
Poor Dispersion ### Cuts - Out 3 COMP.SPEC.) 2-One Check / Day
(A Portion of the of Spec 2-Work execution as per by QA Supervisor as
Homogen Gap 1-Sheet
WI/TECH/03Guage as per 1-Visual / Mixing
per F/QAD/11 .
3.3 / eously (Next production run between F/QAD/24(FINAL Operator 8 72
Process may have to be
Mixing of Mixed Unmix ### Rolls/Sheet 3 COMP.SPEC.) 2-One Check / Day
Final Compoun ed ) reworked in-
Our Guage - 2-Work execution
1-Guage as per as per 1-Visual
by QA Supervisor
/ Mixing as
Batch by d Sheet Comp station before it is
End processed) Out of Spec
Workaway WI/TECH/03
F/QAD/24(FINAL per F/QAD/11 .
Operator 8 72
Strainer with Sheet ound
Mill. Guage As ### Blending - 3 COMP.SPEC.) 2-One Check / Day
per Spec. Out of Spec 2-Work execution as per by QA Supervisor as
WI/TECH/03 perDaily
F/QAD/11
QA Check. 8 72
Pre-mature
- ### - 3 -
Sheet (PFM)
Custom Curing of
No effect
er End Compound
###-- 1 - N/A 1 1
(A Portion of the Improper 24
2-Work execution as per
Exces production run ### Water 2 Visual / Operator 4
sive (Next may have to be WI/TECH/03
Circulation
Temp Process
)
reworked in- Improper 24
of Wire mesh 2-Work execution as per
Strain Our station before it is### Water
chocking
2
WI/TECH/03
Visual / Operator 4
ed End processed) Circulation
Comp Daily QA Check 8`
Homogen ound - ### - 3 -
eously Pinhole in Cured Sheet (PFM)
Mixed Custom
3.4 / er End Tube NO Effect ###- - 1 - N/A 1 1
Compoun
Straining
d with (100% of Product Mesh-size at every 2 48
of Wire Mesh
Correct may have to be Wire-mesh size as per change by
Compoun (Next scrapped. Line ### Size - Out 3
Straining WI/TECH/03 Operator/Prod.
d
Temp & Process Shutdown or stop of Spec
Mesh Mesh Change at
Mesh-change after each Supervisor
free from ) 2 48
ship.) Change every 45 Min /
FM FM in
Our ### 3 45 minutes as per
End Freq. - Not Operator/Prod.
Comp WI/TECH/03
followed Supervisor
Daily QA Check 8 72
ound Loss of Air
- ### - 3 -
Sheet
Mesh (PFM)at
Change
retention Wire Mesh 2 48
Check as per every 45 Min /
(Loss of Primary ### Size - Out 3
Custom Mesh WI/TECH/03 Operator/Prod.
Mesh Change at
er End function-vechile of Spec
Supervisor
inoperable,does ### Change
Pre-mature 3
Check as per every 45 Min / 2 48
not affect
Curing of safe Freq. - Not WI/TECH/03 Operator/Prod.
vechile operation) followed
Improper Supervisor 80
Exces Compound
sive (A Portion of the ### Water 2 As per WI/TECH/03 Daily Check sheet 8
Temp production run Circulation
of may have to be 80
Roll Gap- Manual Check for
Feed
reworked in- ### 2 As per WI/TECH/03 8
Feedstrip strip Out of Spec every Size
with Comp station before it is Daily QA Check
Correct ound processed) ### 3 8 72
3.5 /
Dimensio Sheet (PFM)
Mixing of Custom Uneven Intake by
ns & er End NO Effect ###- - 1 - N/A 1 1
Batch in Extruder
Temp.and Roll Gap-
Feed Mill . ### 3 As per WI/TECH/03 Visual / Operator 8 48
Incorr (Next ( Slight
free from
Cured
Out of Spec
ect Process inconvenience to Cutter Gap
Lump , Dime ) Process, ### - Out of 3 As per WI/TECH/03 Visual / Operator 8 48
nsion Our Operation or Spec,
s of End Operator ,) Daily QA Check
Feed 3 8 72
Sheet (PFM)
strip .
Custom
er End NO Effect ###- - 1 - N/A 1 1
NOTE : WHEN RPN EXCEEDS 100 THEN ACTION PLAN WILL BE INITIATED .

Revision History :

Revision
S No. Revision Date Revision Details Prepared By Checked by Approved By
No

01 00 01.01.2018 As per IATF Requirement.

02 01 27.02.2019 Updation

03 02 15.01.2020 Updation
Updated to address for prevention of
04 03 29.08.2020 Puncture/pinhole.
Updated to address for prevention of
05 04 29.01.2021 weak-joint.
 Documen F/NPD/06
POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PFMEA) Revisio
04
n No.
Product : Automotive Inner Buty Process : Final Compound Mixing ……. Process-03 Revision 29.01.2021

Customer : All Customer Process Responsibility : Technical / QA Respo

Page
nsibilit 1OF 1
Core team : RD/DKS/SNS/AP Process Owner : Production Head
y&
Sub Target Action Results

DETECT
OCCUR
CLASS
Potential cause(s) Current Process Recommen
Process Potential Potential Effects(s) Current Process Control Compl

RPN
SEV
Requirement Mechanism(s) of Control ded
Step/ Failure Mode of Failure (Prevention) etion
Failures (Detection) Action(s) Action SDO R
Function
Visual
1-Every batch/shift
S.G. of 1-Validtion of m/c with
by prod.ofiicer
Compound out of### wts-start of shift 2-Two
2 5 50 -
Spec. 2-Calibration of m/c-once
times/comp/shift by
(A Portion of the in month prod-officer
production run may have 3-One check/day by
3.1 / Correct to be reworked offline
Weighing Weighed (Next and accepted) QA-officer
Un skilled Man Training Plan &
of Master Ingradient
Impro Process
### 2 On Job Training 1 10
Compoun s as per power Effectiveness
Visual
per )
d& Compoun 1-Every batch/shift
Weigh Our
Chemical d Receipy
ment End 1-Validtion of m/c with by prod.ofiicer
s as per Green Tube Wt
Specificati Specificati Weighing Scale wts-start of shift 2-Two
Variation ### 2 5 50
on . on . Faulty 2-Calibration of m/c-once times/comp/shift by
( A portion of the prod
run may have to be in month prod-officer
reworked offline and 3-One check/day by
accepted.) QA-officer
Un skilled Man Training Plan &
### 2 On Job Training 1 10
power Effectiveness
Custom
NO Effect ###- - 1 - Visual N/A 1 1
er End 1-Every batch/shift
8 72
by prod.ofiicer
Mixing
2-Two
### sequence-Out of 3
times/comp/shift by
Spec
prod-officer
3-One check/day by 2 12
QA-officer
Mixing Time-Out
Poor Dispersion ### 2 Auto Cut by Digital Timer
of Spec ,
(A Portion of the
(Next production run
Process may have to be 2 6
Homogen
3.2 / Unmix ) reworked in- Air Pressure of Air Pressure set & Cutt
eous
Mixing of
Batch in
Mixing of
ed Our
Comp End
station before it is### RAM-Incorrect 1 off at Main
Compoun processed) Visual
Kneader ound 1-PLC Controlled
d
Digital Display 2 6
2-Every batch/shift
Dump Temp- by prod.ofiicer
### 1
Out of Spec. 3-Two
times/comp/shift by
prod-officer
4-One
Dailycheck/day
QA Checkby 8 24
- ###- - 1 - QA-officer
Sheet (PFM)
Custom
er End
NO Effect ###- - - 1 N/A 1 1
1-Number of Cuts as per 1-Visual / Mixing 8 72
F/QAD/24(FINAL Operator
Number of Cuts
Poor Dispersion ### - Out of Spec 3 COMP.SPEC.) 2-One Check / Day
(A Portion of the 2-Work execution as per by QA officer as per
Homogen 1-Sheet Guage as per
WI/TECH/03 1-Visual
F/QAD/11 / Mixing
.
(Next production run Gap between 8 72
3.3 / eously F/QAD/24(FINAL Operator
may have to be Rolls/Sheet
Mixing of Mixed Unmix Process ### 3 COMP.SPEC.) 2-One Check / Day
Final Compoun ed ) reworked in- Guage - Out of
2-Work execution
1-Guage as per as per by QA officer
1-Visual as per
/ Mixing
Batch by d Sheet Comp Our station before it is Spec
End processed) Workaway WI/TECH/03
F/QAD/24(FINAL F/QAD/11 .
Operator 8 72
Strainer with Sheet ound
Mill. Guage As ### Blending - Out 3 COMP.SPEC.) 2-One Check / Day
per Spec. of Spec 2-Work execution as per by QA officer as per
WI/TECH/03 F/QAD/11
Daily QA. Check 8 72
Pre-mature
- ### - 3 -
Sheet (PFM)
Custom Curing of
No effect
er End Compound ###- - 1 - N/A 1 1
(A Portion of the 24
Improper Water 2-Work execution as per
Exces production run ### 2 Visual / Operator 4
sive (Next may have to be Circulation WI/TECH/03
Temp Process
)
reworked in- 24
of Wire mesh Improper Water 2-Work execution as per
Strain Our station
chocking
before it is###
Circulation
2
WI/TECH/03
Visual / Operator 4
ed End processed)
Comp Daily QA Check 8`
Homogen ound - ### - 3 -
eously Pinhole in Cured Sheet (PFM)
Mixed Custom
3.4 / er End Tube
NO Effect ###- - 1 - N/A 1 1
Compoun
Straining
d with (100% of Product Mesh-size at every 2 48
of may have to be Wire Mesh Size Wire-mesh size as per change by
Correct ### 3
Compoun (Next scrapped. Line
d
Straining - Out of Spec WI/TECH/03 Operator/Prod.
Temp & Process Shutdown or stop Meshofficer
Change at
free from ) Mesh Change Mesh-change after each 2 48
Our ship.)
every 45 Min /
FM FM in ### Freq. - Not 3 45 minutes as per
End Operator/Prod.
Comp followed WI/TECH/03
Dailyofficer
QA Check 8 72
ound Loss of Air
- ### - 3 -
Mesh
Sheet
Change
(PFM)at
retention 2 48
Wire Mesh Size Check as per every 45 Min /
(Loss of Primary ### 3
Custom - Out of Spec WI/TECH/03 Operator/Prod.
Mesh Change at
er End
function-vechile Mesh Change
Check as per officer
every 45 Min / 2 48
inoperable,does ### Freq. - Not
Pre-mature 3
not affect WI/TECH/03 Operator/Prod.
Curing of safe followed
vechile
Compoundoperation) officer 80
Exces Improper Water
sive (A Portion of the ### Circulation 2 As per WI/TECH/03 Daily Check sheet 8
Temp production run
of may have to be Roll Gap- Out of Manual Check for 8 80
Feed
reworked in- ### 2 As per WI/TECH/03
Feedstrip strip Spec every Size
with Comp station before it is Daily QA Check
Correct ound processed) ### 3 8 72
3.5 /
Dimensio Sheet (PFM)
Mixing of Custom Uneven Intake by
ns & er End NO Effect ###- - 1 - N/A 1 1
Batch in Extruder
Temp.and Roll Gap- Out of
Feed Mill . ### 3 As per WI/TECH/03 Visual / Operator 8 48
free from Incorr (Next ( Slight Spec
Cured
Lump ,
ect Process inconvenience to Cutter Gap - Out
Dime ) Process, ### 3 As per WI/TECH/03 Visual / Operator 8 48
nsion Our Operation or
of Spec,
s of End Operator ,) Daily QA Check
Feed 3 8 72
strip .
Sheet (PFM)
Custom
er End
NO Effect ###- - 1 - N/A 1 1
NOTE : WHEN RPN EXCEEDS 100 THEN ACTION PLAN WILL BE INITIATED .

Revision History :

Revision
S No. Revision Date Revision Details Prepared By Checked by Approved By
No

01 00 01.01.2018 As per IATF Requirement.

02 01 27.02.2019 Updation

03 02 15.01.2020 Updation
Updated to address for prevention of
04 03 29.08.2020 Puncture/pinhole.
 Updated to address for prevention of weak-
05 04 29.01.2021 joint.