Meenakshi molding private limited

Process FMEA
Part No: N127036 Process Responsibility : V.RAVI FMEA Number: MMPL/FMEA/N127036

Model Year(s)/Vehicles(s): Key Date:22.05.13 Prepared by:R.Ramesh

CORE TEAM: S.Govindarajan, G.Sathiyamoorthi, V.Ravi, R.Ramesh Part Name :SEAL FMEA Date (orig):22.05.13 (Rev):02/08.09.2021
Process S C O D
Action Results
e l c e Responsi
Function c ```
Process / v a t R bility & S O D R
Machine Potential Cause(s)/ u Recommended
Product Potential Failure Mode Potential Effect(s) of Failure s r
e P Target e c e P
Description Mechanism(s) of Failure Action(s)
Characteristics s c N Completi Actions Taken v c t N
Prevention Detection t on Date
Requirements

1.Next operation:Product Not meet Specific Requirement

2.customer end:
Wrong Identification Between Incoming Compound Approval
Identification Product Not meet Specific Requirement 6 Improper identification and Handling 2 Work Instruction / Operator Training 5 60
DC and Sticker Report
3.End user:
As per quality Failed to meet Indent Function
Receipt of plan/ Customer
10 compound Requirement
(NBR70) FM/7.1/01/71,FM
/7.5/21
1.Next operation: Shortage Of Material 2.customer end :
Weight Difference Between DC Customer dissatisfaction Weighing Balance Verification
Weight 5 Digital Weighing Scale Malfucnctioning 2 Calibration Of weighing Scale 6 60
and ID Sticker 3.End user: Record
Failed to meet Indent Function

1.Next operation Compound Unusable , Flow , Crack on

product 2.customer end : Not meeting Physical Properties
No Scorching Scorching Resulting in funtional faliure 8 Aging Of compound 2 Daily FMB Rhelogical Property Inspection 5 80
3.End user:
Failed to meet Indent Function

1.Next operation: Variation in Blank Weight Causing Flow

Defect , Short fill2.customer end : Assembly Problem Improper Roller Setting -
Sheeting Mill Minimum 4 3 Work Instruction / Operator Training First Off Inspection 5 60
3.End user: Minimum / Non Uniform
Failed to meet Indent Function

Nip setting

1.Next operation Compound Unusable 2.customer end :

Flow , Crack on product , Not meeting Physical Properties
Improper Sheet Size ( Maximum /
Maximum Resulting in funtional faliure 4 3 Work Instruction / Operator Training First Off Inspection 5 60
Non uniform)
3.End user:
Failed to meet Indent Function

1.Next operation: Variation in Blank Weight Causing Flow

Defect , Short fill
2.customer end: Improper Roller Setting -
Under Size 4 3 Work Instruction / Operator Training First Off Inspection 5 60
Assembly Problem Minimum / Non Uniform
3.End user:
Failed to meet Indent Function
Sheeting Mill Sheet Thicness

1.Next operation Excess Flsh Thickness on the Product Matt

20 Blanking
2.customer end :Assembly Problem Improper Roller Setting - Maximum /
Over Size 4 3 Work Instruction / Operator Training First Off Inspection 5 60
3.End user: Non Uniform
Failed to meet Indent Function

1.Next operation: Variation in Blank Weight Causing Flow

Defect , Short fill
2.customer end: Route card
Minimum 4 Improper Marking On the sheet 3 First Off Inspection 5 60
Assembly Problem ( Sheet size Descriped in )
3.End user:
Uniform Sizing Failed to meet Indent Function

1.Next operation Excess Flsh Thickness on the Product Matt

2.customer end :Assembly Problem Route card
Maximum 4 Improper Marking On the sheet 3 First Off Inspection 5 60
3.End user: ( Sheet size Descriped in )
Failed to meet Indent Function

Scissor / Blade 1.Next operation: Variation in Blank Weight Causing Flow

Cutting / Knife Defect , Short fill
2.customer end: Improper Sheet Size ( Minimum / Non
Under Size 4 3 Work Instruction / Operator Training First Off Inspection 5 60
Assembly Problem uniform)
3.End user:
Failed to meet Indent Function
Sheet Breadth

1.Next operation: Excess Flsh Thickness on the Product

Matt
2.customer end: Improper Sheet Size ( Maximum /
Over Size 4 3 Work Instruction / Operator Training First Off Inspection 5 60
Assembly Problem Non uniform)
3.End user:
Failed to meet Indent Function

Form No.FM/7.1/01/09 Page 01 of 04

Meenakshi molding private limited
Process FMEA

Part No: N127036 Process Responsibility : V.RAVI FMEA Number: MMPL/FMEA/N127036

Model Year(s)/Vehicles(s): Key Date:22.05.13 Prepared by:R.Ramesh

CORE TEAM: S.Govindarajan, G.Sathiyamoorthi, V.Ravi, R.Ramesh

Part Name :SEAL FMEA Date (orig):22.05.13 (Rev):02/08.09.2021
Process S C O D R
Function e l c e P Responsi Action Results
v a c Current Process Controls t N bility &
Machine Product Potential Cause(s)/ Recommended S O D R
Potential Failure Mode Potential Effect(s) of Failure s u e Target
Description Characteristics Mechanism(s) of Failure Action(s) e c e P
s r c Completi Actions Taken v c t N
Prevention Detection t on Date
Requirements
1.Next operation: Variation in Blank Weight Causing Flow
Defect , Short fill
2.customer end:
Under Weight 4 Improper Blank Cutting 4 Operator Training First Off Inspection 5 80
Assembly Problem
3.End user:
Failed to meet Indent Function
Manual Blank
20 Blanking Blank Weight
Cutting
1.Next operation: Excess Flsh Thickness on the Product
2.customer end:
Over Weight Assembly Problem 4 Improper Blank Cutting 4 Operator Training First Off Inspection 5 80
3.End user:
Failed to meet Indent Function

Blank Position provided Based on

7 Improper Blank Positioning 3 Feasible / Blank Size controlled in In process inspection 5 70
Blank Cutting Machine

Die Preventive Maintenace Being

7 Die closing Not ok 2 Poka yoke Report 5 70
Followed

1.Next operation: Rejection Part Received Die Preventive Maintenace Being Online Inspection / Poka yoke
7 Mold Stain 3 5 70
Flow , Shortfill, curing rejection, 2.customer end: Assembly Problem Followed Report
No visual Defects
Air bubbles, 3.End user:
Failed to meet Indent Function
7 Remaining Flash On Mould 2 Air cleaning On every shot Visual Check By operator 5 70

7 Improper Breathing 2 Breathing Controlled Through PLC Online Inspection 4 56

7 Air Entrapped 3 Air vend Provided On Mold Visual Check By operator 5 70

1.Next operation: Under Cure Product

PLC Control / Patrol Checking /
Curing Time low 2.customer end: Assembly Problem 3.End user: 7 Wrong Setting ,Timer Failure 2 First Off Inspection 4 56
Machine Maintenece
Failed to meet Indent Function
30 Molding ACMM

Curing Time

1.Next operation: Flow and Overcured Product Noticed

2.customer end:
PLC Control / Patrol Checking /
Curing Time high Assembly Problem 7 Wrong Setting ,Timer Failure 2 First Off Inspection 4 56
Machine Maintenece
3.End user:
Failed to meet Indent Function

1.Next operation: Under Cure Product 2.customer end:

Wrong Setting,Heater PLC Control / Patrol Checking /
Temperature Lower Assembly Problem 3.End user: 7 2 First Off Inspection 4 56
Failure,Temperature Controller Failure Machine Maintenece
Failed to meet Indent Function

Temperature

1.Next operation: Flow and Overcured Product Noticed

Wrong Setting,Heater PLC Control / Patrol Checking /
Temperature Upper 2.customer end: Assembly Problem 3.End user: 7 2 First Off Inspection 4 56
Failure,Temperature Controller Failure Machine Validation
Failed to meet Indent Function

Form No.FM/7.1/01/09 Page 02 of 04

Meenakshi molding private limited
Process FMEA

Part No: N127036 Process Responsibility : V.RAVI FMEA Number: MMPL/FMEA/N127036

Prepared by:R.Ramesh
Model Year(s)/Vehicles(s): Key Date:22.05.13
CORE TEAM: S.Govindarajan, G.Sathiyamoorthi, V.Ravi, R.Ramesh
Part Name :SEAL FMEA Date (orig):25.08.2020 (Rev):02/08.09.2021
Process S C O D
Action Results
Function e l c Current Process Controls e Responsib
v a c t R ility &
Machine Product Potential Cause(s)/ Recommended
Potential Failure Mode Potential Effect(s) of Failure s u e P Target S O D R
Description Characteristics Mechanism(s) of Failure Action(s)
s r c N Completio Actions Taken e c e P
Prevention Detection t n Date v c t N
Requirements

1.Next operation: Mat thickness in higher side , Flow

2.customer end: Preventive Manitenance Being
Wrong Setting, Pressure Gauge Maintenence Check List / First
Pressure - Lower Assembly Problem 7 2 Followed / Machine Maintenece / 5 70
Failure Off Inspection
3.End user: Work Instruction
Failed to meet Indent Function

ACMM Pressure

1.Next operation: Flow 2.customer end : Assembly Problem Preventive Manitenance Being
Wrong Setting, Pressure Gauge Maintenence Check List / First
Pressure - Upper 3.End user: 7 2 Followed / Machine Maintenece / 5 70
Failure Off Inspection
Failed to meet Indent Function Work Instruction

Blank Position provided Based on

7 Improper Blank Positioning 2 Feasible / Blank Size controlled in In process inspection 5 70
Blank Cutting Machine

Die Preventive Maintenace Being

1.Next operation: Difficult In deflashing 7 Die closing Not ok 2 Poka yoke Report 5 70
Followed
Product Profile Unuiform Shape 2.customer end: Assembly Problem
3.End user: Failed to meet Indent Function Die Preventive Maintenace Being Online Inspection / Poka yoke
7 Mold Stain 2 6 84
Followed Report

7 Remaining Flash On Mould 2 Air cleaning On every shot Visual Check By operator 4 56

30 Molding
Cutting Edge Dimension Maintained
7 2 Tool Approval Sample Inpesction report 5 70
1.Next operation: Difficult In deflashing 2.customer end: Minimum In Tool Manufacturing
Assembly Problem
Short Cutting Edge Thickness
3.End user:
Failed to meet Indent Function
7 Under Blank Weight 2 Work Instruction / Operator Training In process inspection 5 70
Mold Matt Thickness

1.Next operation:
Difficult In deflashing 2.customer end: Assembly Problem
Excess Cutting Edge Thickness
3.End user:
Failed to meet Indent Function
Operator Checking Route Card /
7 Mold cutting Edge Worn out 2 Tool Validation 5 70
Patrol Checking - Route Card

1.Next operation: -
- 2.customer end: Assembly Problem Mold Dimension Maintained In
Under Size 7 2 Tool Validation Sample Inspection Report 5 70
3.End user: minimum / Core Pin Damages
Failed to meet Indent Function

Dimension

1.Next operation: -
- 2.customer end: Assembly Problem Mold Dimension Maintained In
Over Size 7 3 Tool Validation Sample Inspection Report 5 70
3.End user: maximum / Stain Mark
Failed to meet Indent Function
Curing Time and Oven log / 100%Visual
40 Post Curing Oven Improper Post Curing Poor Physical properties 7 Low Voltage / Improper Timing 2 Work Instruction 7 98
Temperature Inspection

1.Next operation: Flashes on Product (Rework) 2.customer

end: Assembly Problem Improper Setting of Process Predefined Parameter Controlled
Short Removal Of Flash 7 2 Route Card 7 98
3.End user: Parameter Through PLC / Operator Training
Failed to meet Indent Function

Manual
40 Deflashing Removal Of Flash

1.Next operation: Cut Marks , Tearing 2.customer end:

Assembly Problem Improper Setting of Process Predefined Parameter Controlled
Excess Removal Of Flash 7 2 Route Card 7 98
3.End user: Parameter Through PLC / Operator Training
Failed to meet Indent Function

Form No.FM/7.1/01/09 Page 03 of 04

Meenakshi molding private limited
Process FMEA

Part No: N127036

Process Responsibility : V.RAVI FMEA Number: MMPL/FMEA/N127036

Model Year(s)/Vehicles(s): Key Date:22.05.13 Prepared by:R.Ramesh

CORE TEAM: S.Govindarajan, G.Sathiyamoorthi, V.Ravi, R.Ramesh Part Name :SEAL FMEA Date (orig):25.08.2020 (Rev):02/08.09.2021
S C O D Action Results
Process e l c e Responsi S O D R
v a c Current Process Controls t
Function R bility & e c e P
Machine Product s Potential Cause(s)/ u e Recommended
Potential Failure Mode Potential Effect(s) of Failure P Target v c t N
Description Characteristics s Mechanism(s) of Failure r c Action(s) Actions Taken
N Completi
t on Date
Prevention Detection
Requirements

1.Next operation: NA 2.customer end:

100% Visual Missing Of Visual Defects Operator Inadquate training to
Assembly Problem 3.End user: 7 2 Work Instruction 100% Visual Inspection / PDIR 7 98
Inspection Short fill,Flow,Cut mark detect / Identified the Defects
Failed to meet Indent Function

Test Report verification and

7 Improper Testing Method / Approval 2 Test Personnel Training 4 56
1.Inspection 1.Normal Eyes 2. approval
50 2.Pre delivery As per Quality
Inspection Plan
1.Next operation: NA Malfutionaing Of Inspectuion Periodic inspection of test
Dimension Approval Of defect Parts 2.customer end:Fitment Problem 3.End user: Failed to meet 7 equipments
2 Calibration of equipments
equipments
4 56
Indent Function

Untrained operator , Inspector IMTE Trained operator, Periodcal Calibration

7 2 Final Inspection Report 5 70
Variation of IMTE

1.Next operation: -Function2.customer end: Dis-

Improper counting / Malfunctioning Work instruction / Periodcal Weighing Balance Verification
Shortage satisfication 3.End user: 7 2 5 70
the counting machine Calibration of IMTE Record
Failed to meet Indent Function

Packing and Counting

60 Counting
Approval Machine

1.Next operation 2.customer end: Fitment Problems

Mix up Of Different Product Ref 7 Improper Identification and Handling 2 Operator Training Work instruction 5 84
3.End user: Not Applicable

Form No.FM/7.1/01/09 Page 04 of 04

POKA YOKE IMPLEMENTATIONS STATUS

SI.NO PROCESS NO PROCESS PRODUCT CHARECTRISTICS POKA YOKE WORKING PRINCIPLES QTY IMPLEMENTATION STATUS IF NOT WORKING REACTION PLAN

Implemented and working condition 1.M/C Stop and inform to supervisor and correct the mould.
1 30 Moulding Flash,Un uniform shape Mould Top bottom plate hinged Mould proper seated top and bottom plate,No excess flash,Un uniform shape occurred 1
Good. 2.Spare mould used.

Amentmend Record
Si No AMENDMENT DETAIL DETAIL OF CHANGE REASON FOR CHANGE CURRENT REV NO / DATE REVISED REV NO / DATE RESPONSIBILITY APPROVED BY ISSUED BY

1 New Release _ _ 0/22.05.13 _ R.Ramesh G.Sathiyamoorthy S.Govindarajan

2 PFD REVISED PDF FORMAT CHANGE PDF FORMAT CHANGED 0/22.05.13 01/15.04.15 R.Ramesh G.Sathiyamoorthy S.Govindarajan