POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)

ITEM: TEMP DOOR PROCESS RESPONSIBILITY: Production Manager FMEA NUMBER: PFMEA /11
MODEL YEAR(S)/VEHICLE(S): B515 KEY DATE: 18.11.2013 PREPARED BY: U BalaRaghavan
CORE TEAM: Core Team: E.Vijayakkumar, U.BalaRaghavan A.R.Loganathan, K.Ganesh ,Elango FMEA DATE(ORIG.): 06.06.2013
ITEM NUMBER: VPBE2H-18K413-AB FMEA DATE(REV.):30.05.2021

C
CURRENT PROCESS CONTROL ACTION RESULTS
PROCESS S L O D R RECOMME RESP.& TARGET
POTENTIAL FAILURE POTENTIAL CAUSE(S) S O D R
FUNCTION/ POTENTIAL EFFECTS OF FAILURE E A C E P NDED COMPLETION
MODE S /MECHANISM(S) OF FAILURE PREVENTION DETECTION ACTIONS TAKEN E C E P
REQUIREMENTS V C T N ACTION (S) DATE
S V C T N
Material Misusing, Traceability Training Provided/Raw
Grade & Properties Un Trained Operator/Standard not
confusion & Prosperities not 4 3 Material Inspection Standard Check the QC at the time of receiving 7 84
Spec Vs Actual Variation Available
meet the requirements Provided
OP #10 To Receive Raw Material Appearance Packing Damage, Foreign Un Trained Operator/improper Raw Material Inspection
Raw Material as per Incoming 2 5 Check the QC at the time of receiving 7 70
Conformance Material Mix Up & Wet Handling Standard Provided-
Receiving Inspection Inspection Raw Material
Standard Variation in Weighing
Quantity/ Weight Less Quantity(Quantity not meet Balance/Untrained Sampling Plan done by using
3 4 1 Bag/1 Lot 7 84
Variation as per Requirement) Operator/Improper Material Weighing Scale
Handling due to transport
Operator check the Loader
OP #20 Insufficient Jobs not meet as per
Hopper loader Loader Problem Material not free flowing 3 2 regularly instructed by Qc Loader to be done auto feed 6 36
Hopper Conveying Customer Requirements
Inspector

Product Quality effected(Molding Untrained Operator / variation in Process Parameter freeze in Checked By QC/Supervisor at the
Wrong Parameters 7 3 4 84
Defect occur) Controller Display Spec sheet Start Time & every 2hrs Once

Process Parameter Checked By QC/Supervisor at the

Short Shot Fitment problem 6 Low Injection Pressure / Speed 2 5 60
monitoring Start Time & every 2hrs Once

Process Parameter Checked By QC/Supervisor at the

FLASH Appearance Not Good 6 Low Injection Pressure / Speed 2 5 60
monitoring Start Time & every 2hrs Once

Process Parameter Checked By QC/Supervisor at the

Warpage Fitment problem 6 Mold Temperature variation 2 5 60
monitoring Start Time & every 2hrs Once

Process Parameter
Virgin Material not monitoring during start up & Checked By QC/Supervisor at the
Twist Issue Fitment problem 6 2 5 60
used/Temperature variation check on the issue slip for Start Time & every 2hrs Once
virgi material entry.
Process Parameter
OP #30 monitoring during start up Checked By QC/Supervisor at the
To Provide the Moulding Short length Fitment problem 6 HRS Temperature Variation 2 5 60
Plastic Injection and product length variation Start Time & every 2hrs Once
Parts as per Drawing during start up and patrol
Moulding
Component Validation at the
Check first Off Piece at the time of
Visual Improper Aesthetic 5 Mould Problem 2 time of Mould Procurement 5 50
mould loading
Or Rectification

Low(or) High Injection Pressure /

Process Parameter
Part Weight Less Weight or Excess Weight 6 Low (or) High Shot weight / Low 3 5 90
monitoring
(or) High Temperature

Production date and shift not

mentioned
Part weight & traceability details
should be written on the part just
Traceability details
above the Ford Logo/Calender
punch should be checked for
YEAR/MONTH/DATE /SHIFT for
correctness
Untrained operator/Lack of
5 2
awareness
Checked By QC/Supervisor at the
Start Time & every 1hr Once
Training has been given and
5 50
educated

OP#40 Improper Packing

Damage & Deformation Fitment problem 6 Separate Partition Bins 3 Packing standard Packing slip/ Bin standard 4 72
WIP Storage Standard

Product Quality effected(Molding Untrained Operator / variation in Process Parameter freeze in Checked By QC/Supervisor at the
Wrong Parameters 7 3 4 84
Defect occur) Controller Display Spec sheet Start Time & every 2hrs Once

Process Parameter Checked By QC/Supervisor at the

Short Shot Air Leakage 6 Low Injection Pressure / Speed 2 5 60
monitoring Start Time & every 2hrs Once

Process Parameter Checked By QC/Supervisor at the

FLASH Appearance Not Good 6 Low Injection Pressure / Speed 2 5 60
monitoring Start Time & every 2hrs Once

Process Parameter Checked By QC/Supervisor at the

Air Bubbles Air Leakage 6 High barrel temperature 2 5 60
monitoring Start Time & every 2hrs Once

Training Provided to Checked By QC/Supervisor at the

Damage Fitment problem 6 Improoper Door Insert 2 5 60
Operator Start Time & every 2hrs Once
OP #50 Component Validation at the
To Provide the Moulding Check first Off Piece at the time of
Rubber Injection Visual Improper Aesthetic 5 Mould Problem 2 time of Mould Procurement 5 50
Parts as per Drawing mould loading
Moulding Or Rectification
 C
CURRENT PROCESS CONTROL ACTION RESULTS
PROCESS S L O D R RECOMME RESP.& TARGET
POTENTIAL FAILURE POTENTIAL CAUSE(S) S O D R
FUNCTION/
OP #50 POTENTIAL EFFECTS OF FAILURE E A C E P NDED COMPLETION
To Provide
MODE
the Moulding S /MECHANISM(S) OF FAILURE PREVENTION DETECTION ACTIONS TAKEN E C E P
REQUIREMENTS
Rubber Injection V C T N ACTION (S) DATE
Parts as per Drawing S V C T N
Moulding

Low(or) High Injection Pressure /

Process Parameter
Part Weight Less Weight or Excess Weight 6 Low (or) High Shot weight / Low 3 5 90
monitoring
(or) High Temperature

Production date and shift not

mentioned
Part weight & traceability details
should be written on the part just
Traceability details
above the Ford Logo/Calender
punch should be checked for
YEAR/MONTH/DATE /SHIFT for
correctness
Untrained operator/Lack of
5 2
awareness
Checked By QC/Supervisor at the
Start Time & every 1hr Once
Training has been given and
educated and location fixed 5 50
above the Ford Logo

OP#60
To remove Unwanted Burr Not Removed / Operator not Training Provided to Visual Inspection Standard Displayed
De - Flashing & Flashes Appearance Not Good 5 3 5 75
Material trained Operator near the De flashing Area
visual Inspection

Training Provided &

Dimensional Problem Prepared Skill Matrix ,Final
Gauge not Answering 6 3 Inspection Standard 4 72
Displayed near the Final
OP #70 To Check the Product Final Inspection Standard Not Area Final Inspection report
Final Inspection Parameters Twist Issue Provided/Inspector not trained

Production date and shift not Training has been given and
Traceability details mentioned 5 2 educated and location fixed 5 50
above the Ford Logo

OP #80 Packing as per Packing

Customer Dissatisfaction Short Quantity 7 Incorrect counting 2 Packing standard Packing slip/ Bin standard 6 84
Packing Standard

OP #90 Improper Daily dispatch planning

Delivery at the right time Customer Dissatisfaction Production planning not Proper 6 1 Delivery invoice 4 24
Dispatch planning procedure
IF SEVERITY 9 or 10 and or OCURRENCE 9 or 10 and or DETECTION 9 or 10 and or RPN EXCEED 100 REACTION PLAN WILL BE FOLLOWED
REVISION HISTORY
REVISION NUMBER REVISION DATE DETAILS OF REVISION PREPARED CHECKED APPROVED
01 27.02.2021 Process updation for twist issue Mr.Loganathan A R Mr.Balaraghavan U Mr.Krishnamoorthi V
02 4/29/2021 Part weight out of spec issue and traceability location fixed condition Mr.Loganathan A R Mr.Balaraghavan U Mr.Krishnamoorthi V
03 31.05.2021 Process updation for short length issue Mr.Loganathan A R Mr.Balaraghavan U Mr.Krishnamoorthi V

SIGNATURE OF CFT MEMBERS:-

DAEJUNG MOPARTS PVT LTD

 CONTROL PLAN
Phase Covered : Proto Type Pre-Launch Production
ISSUE DATE:- 18.11.2019
Control Plan Number NO DATE REASON PRD CKD APD
Core Team: E.Vijayakkumar, U.BalaRaghavan A.R.Loganathan, K.Ganesh ,Elango
CP/B515/05
PREPARED CHECKED APPROVED
Part Number Key Contact PHONE Latest Change Level
00 18/11/2019 Initial BALAJI HARIHARAN HARIHARAN
VPBE2H-18K413-AB U.BalaRaghavan 9150010294
A
P
Part Name/Description Supplier/Plant Approval/Date Date(Orig) Customer Quality Approval /Date(If Reqd) P
01 27.02.2021 B515 Temo door Twist issue Mr.Loganathan A R Mr.Balaraghavan U Mr.Krishnamoorthi V R
O
V
A Mr.Loganathan A R Mr.Balaraghavan U Mr.Krishnamoorthi V
VLV & SE ASY - HTR AIR L
TEMP CONTR
DAEJUNG MOPARTS PVT LTD Part weight out of spec issue and
02 29.04.2021 Mr.Loganathan A R Mr.Balaraghavan U Mr.Krishnamoorthi V
traceability location fixed condition

CUSTOMER Supplier Code Date(ECO) Other Approval/Date(If Reqd)

03 31.05.2021 process updation for short length Mr.Loganathan A R Mr.Balaraghavan U Mr.Krishnamoorthi V
VISTEON 80002191 issue

Characteristics Methods
Part/ Process Name / Machine. Special Product/Process Evaluation/ Sample Reaction Plan
Process Operation Device Jig. Char Mistake Proofing
Number Description Tools For Mtg No Product Process Class Specification Measurement Size Freq Control Method IN CHARGE
& Corrective Action

Tolerance Technique

1 PP 40% As per Incoming inspection std - Raw material QC Inspector R1

In-coming ( QUA/D/01-03)
10 Inspection - Raw
material Rubber Material As per Incoming inspection std - Raw material
2 TPE ( QUA/D/01-10)

1 Free Movement of Material Temperature 70℃ ±10℃ Temp. Controller 100% Every shift Daily production report Production Hopper to be checked for it's proper working.
PP 40% Operator to be instructed
20 Raw Material Hopper Dryer
Preheating Free Movement of Material
2 Rubber Material No Preheating - - - - Daily production report Production -
TPE

Pressure, Time, As per POS ; check for all parameter Setting approval
as per SOS during start up. Incase of Every Setting report ,daily QC Inspector
RM ONLY VIRGIN TO BE USED Speed, any parameter out of spec,inform to PLC - every shift production report,Material issue slip monitoring & Operator Check for PLC
Temperature production manager for rectification monitoring on FML on patrol report.

Visual/Checking
A Appearance Free from Flashes,short mold & Twist 100% Every shift Operator
Fixture

Plastic Injection Injection

30 Molding M/C B DIMENSIONS 1,.Check HRS temperature in setting approval sheet
Molding 1 Dia Ø12.00±0.07 VERNIER/GAUGE by production and No deviation allowed.
(350 Ton)
5 Nos at Every Setting 2. During start up and Patrol Inspection check for all
2 Dia Ø17.00±0.07 VERNIER/GAUGE every 2 - dimensions as per control plan and record it .In case R3
235.0±0.25 hrs First/Middle/Last Off of NG , immediately stop the production and arrange
once Report for correctiveaction
3 Length VERNIER/GAUGE QC Inspector
Free from short length 3. 100% check on checking fixture for twist issue
rectification
100% inspection on each and
C Part weight 118.1±3gms WT/MACHINE
every part

40 WIP Storage Packing Bins Free from Deformation As per packing Every Lot FIFO Packing slip Operator R4
Standard
Pressure, Time, As per POS Every Setting Setting approval
QC Inspector
Speed, PLC - report ,daily Check for PLC
Temperature every shift production report
Operator

Free from Flashes, short mold and

A Appearance Visual 100%
Damage
5 Nos Every Setting
B DIMENSIONS - -
5 Nos First/Middle/Last Off
Report
Rubber Injection Injection Part weight 126.2±0.5gms
50 Molding Molding M/C
(200 Ton) Setting approval report Operator/Operat
Part weight on each part or/QC inspector R2
Patrol inspection Report
C WT/MACHINE 100% inspection on each and
Part weight & traceability details should every part
be written on the part just above the Ford
Traceability detail on part Logo/Calender punch should be checked
for YEAR/MONTH/DATE /SHIFT for
correctness

Free from a)Short Mould

A b)Silver Streak c)Flow Mark
Appearance d)Discoloration e) Twist

60 De -Flashing & Knives Visual 100%

Visual/Length checking fixture Operator Reject The Component
Visual Inspection 5 Nos /Every 2 Hrs QC Inspector
 60 De -Flashing & Knives Visual 100%
Visual/Length checking fixture Operator Reject The Component
Visual Inspection Part weight & traceability details should 5 Nos /Every 2 Hrs QC Inspector
Part Weight & Traceability detail be written on the part just above the Ford
B Logo/Calender punch should be checked
on part for YEAR/MONTH/DATE /SHIFT for
correctness

70 Final Inspection As per final inspection standard (QUA/D/18) Final Inspection Report QC Inspector R3
Every out going
80 Packing Packing Bins Free from Deformation As per packing Counting 100% from Final Packing slip Operator R4
Standard inspection
90 Dispatch Logistics Packing quantity - - Every dispatch DC & Invoice Operator R4
Reaction plan Corrective action

R1: Return & Replace The Material

R2:Inform to shop supervisor,Check 100 %,Rework the Material,Scrap the rejection,Analyze the problem

R3:Reject / rework & Finalinspector's to be strictly instructed for following the sampling plan properly & inspect the job with proper lighting

R4:Recounting, enter the correct quantity in slip & Packing operator to be instructed severely to ensure the packing Qty with Packing standard

DOC NO:QUA/D/22-158 REV NO&DATE: 01/31.05.2021 DAEJUNG MOPARTS PVT LTD