MAPL

FMEA No-
POTENTIAL FAILURE MODE AND EFFECT ANALYSIS ( PROCESS)
Rev No / Date
Part Name- WATER PUMP HOUSING Part No. D10369520A Rev.Details 0
F-7.3.1-01
Vehicle Model- AVL Customer M/S Escorts Kubota Process Responsibility- Mr. Mohit
Name Mr. Lovelaish Dassi Mr. Mohit Mr. Rahul Mr. Rajkumar
Core Team- Customer Approval (If Reqd.)
Sign

OCCURANC

OCCURANC
DETECTION

DETECTION
SEVERITY

SEVERITY
Process Function / Resp. &
Potential Failure Potential Cause(S) Current Process Control Current Process Control Recommended Target Action
Potential Effect of Failure CLASS RPN RPN

E
Mode Mechanism (S) of Failure Prevention Detection Action (S) Completion Taken
Requirement Date
Op.

Cause or Failure

RPN after action

the effect on the

has been taken.

How often does

Rate each and

recalculate the
No.

you detect the

How severe is

How well can

Failure Mode

What are the

the Cause or

reducing the
occurrence,
decreasing
customer?

detection?
severity or
actions for

improving
In what ways What is the impact of the What are the existing controls

Mode?
occur?
What are the What are the causes of How do you detect the Cause

CTQ
can the process Failure Mode on the and procedures that prevent the
process steps? the Failure Mode? or Failure Mode?
step go wrong? customer? Cause or Failure Mode?

SQM provided to supplier and

Material(as cast
No Traceability of raw material instruction given to recievieng store
part) received Supplier is not aware about
in case of any failure at 8 1 i.e. material received only if Visual check at RQC stage 5 40
without the specific requirements.
customer end. identification tag is available on
identification tag
Ingot.

Decrease bond strength Instruction provided to supplier and

10. Receiving of Without shot blast Supplier is not aware about
between non blasted surface 7 1 also at recievieng store i.e. material Visual check at RQC stage 5 35
material the specific requirements. Send Material Receipt
I Raw Material(as and the protective coating. received only if it is shotblasted.
back to supplier Engineer
cast part)

Instruction provided to supplier and

Change in mechanical Material not properly also at recievieng store i.e. material
Oxidized material 8 1 Visual check at RQC stage 5 40
properties preserved at supplier end. received only if it is free from
oxidation

Patrolling inspection on
Improper or loose
uneven facing leakage issue after assy 6 3 Set up approval hourly basis 5 90
clamping of part
n=1,c=0 per hr
Facing rough first
Guidance given to Shop
10 Side(GASKET
operator/WI supervisor
SEAL SIDE) Patrolling inspection on
fitment isuue at customer
Less height Initial setup not done 3 Set up approval hourly basis 5 90
end
n=1,c=0 per hr

Tool wear out. Tool life monitoring sheet Inprocess inspection (MAPL-
. 4 5 100
F-QA-02) after every hour
Reaming operation fails and
Dia oversize 5 Wrong tool selection i.e.
roughness not maintain
length of tool not as per 3 Only skilled & trained operators FPA &LPA (MAPL-F-QA-03) 5 75
Rough boring Guidance given to Shop
20 our requirement can perform the operation in the to be done at start & end of
dia 38.067-0.020 operator/WI supervisor
guidance of supervisor process
Tool run out 3 5 75
Concentricity out Program may be Inprocess inspection (MAPL-
2 Program locked 7 70
tampered F-QA-02) after every hour

Only skilled & trained operators FPA &LPA (MAPL-F-QA-03)

If operation missed then
assembly not possible at
customer end
Negligiency of operator 3 to be done at start & end of 5 90
perform the operation.
6 process & Inprocess
Operator unaware of W.I. displayed for such inspection (MAPL-F-QA-02)
3 after every hour 5 90
abnormal situation conditions

Runout of tool 3 Only skilled & trained operators FPA &LPA (MAPL-F-QA-03) 5 90
If oversize then not
assembled with its mating can perform the operation in the to be done at start & end of
6 Wrong tool selection i.e. guidance of supervisor process & Inprocess
Drill Ø9±0.2 part at customer end. length of tool not as per 3 5 90
(6 Holes) . inspection (MAPL-F-QA-02)
Customer dissatisfaction our requirement
Program may be after every hour
tampered 2 Program locked 7 84
Tool wear out. Tool life monitoring sheet
4 5 100
.
Wrong tool selection i.e. FPA &LPA (MAPL-F-QA-03)
If undersize then not Only skilled & trained operators to be done at start & end of
length of tool not as per 3 5 75
assembled with its mating can perform the operation in the process & Inprocess
5 our requirement
part at customer end. guidance of supervisor
Tool run out 3 inspection (MAPL-F-QA-02) 5 75
Customer dissatisfaction
after every hour
Program may be
2 Program locked 7 70
tampered
 MAPL
FMEA No-
POTENTIAL FAILURE MODE AND EFFECT ANALYSIS ( PROCESS)
Part Name- WATER PUMP HOUSING Part No. D10369520A
Rev No / Date
Rev.Details 0
F-7.3.1-01
Vehicle Model- AVL Customer M/S Escorts Kubota Process Responsibility- Mr. Mohit
Name Mr. Lovelaish Dassi Mr. Mohit Mr. Rahul Mr. Rajkumar
Core Team- Customer Approval (If Reqd.)
Sign

OCCURANC

OCCURANC
DETECTION

DETECTION
SEVERITY

SEVERITY
Process Function / Resp. &
Potential Failure Potential Cause(S) Current Process Control Current Process Control Recommended Target Action
Potential Effect of Failure CLASS RPN RPN

E
Mode Mechanism (S) of Failure Prevention Detection Action (S) Completion Taken
Requirement Date
Op.
No. Mounting hole Tool may be offsetted 3 5 75
drilling, spot face & FPA &LPA (MAPL-F-QA-03) Guidance given to Shop
30
boss height to be done at start & end of operator/WI supervisor
maintain Misaligned with its mating Fixture may be offsetted 3 Only skilled & trained operators 5 75
Mounting hole process & Inprocess
part at customer end 5 can perform the operation in the
location out inspection (MAPL-F-QA-02)
Customer dissatusfaction guidance of supervisor
after every hour with
Part not clamped properly 4 receiving gauge 5 100

May result hard to assemble FPA &LPA (MAPL-F-QA-03)

at customer end i.e. Not cleaned properly Only skilled & trained operators to be done at start & end of
Spot Face tightening of bolt with mating 3 because of improper 4 can perform the operation in the process & Inprocess 5 60
part. Customer clamping guidance of supervisor inspection (MAPL-F-QA-02)
dissatisfaction after every hour
Wrong tool selection i.e. FPA &LPA (MAPL-F-QA-03)
length of tool not as per 3 to be done at start & end of 5 75
Customer dissatisfaction our requirement
5 . process & Inprocess
due to oversize
Program may be 2 Program locked inspection (MAPL-F-QA-02) 7 70
Boss Height 50 tampered after every hour
not as per Tool wear out.
specification 4 FPA &LPA (MAPL-F-QA-03) 5 100
.
to be done at start & end of
Customer dissatisfaction Only skilled & trained operators
5 Wrong tool selection i.e. process & Inprocess
due to undersize perform the operation
length of tool not as per 3 inspection (MAPL-F-QA-02) 5 75
our requirement after every hour

Only skilled & trained operators

Operation Missing causes
fitment failure at customer
end.
Fitment failure at customer
end Customer
Drill Ø10 not ok
dissatisfaction due to
oversize dia.
Fitment failure at customer
end Customer
dissatisfaction due to
undersize dia.
Dia. 10 Taper hole
40
drilling
Drill location Fitment failure at customer
26.5 from pipe end because of offset
centre not ok location
Carelessness of operator
6
Mixing of ok and
inprocess parts
6 Wrong tool selection
Tool wear out
5 FPA &LPA (MAPL-F-QA-03)
Wrong tool selection
Improper clamping of part
7
Not using fixture for
drilling.
3 5 90
perform the operation
Location for OK parts &
3 5 90
inprocess parts clearly identified.
Only skilled & trained operators
3 5 90
perform the operation
Tool life monitoring sheet
4 5 100
Only skilled & trained operators to be done at start & end of
3 5 75 Guidance given to Shop
perform the operation process & Inprocess
operator/WI supervisor
inspection (MAPL-F-QA-02)
Only trained & skilled operators after every hour with PPG
4 3 84
perform the operation.
3 Use of Fixture. 3 63

May result in fitment failure *Not using the fixture Use of Fixture.
Angle 15° not as
of thermostat at customer 5 *Part not clamped 4 Only trained & skilled 5 100
per specification
end properly operators perform the operation.

Use of Fixture.
Not as per required
Drill Depth 42 Customer dissatisfaction 5 3 Only trained & skilled 5 75
specification
operators perform the operation.
*Carelessness of
operator. *Mixing
Due to absence of leak hole
of processed and 4 5 100
water pump may jammed
unprocessed ones.
Use of Fixture.
5 Only trained & skilled
*Carelessness of operators perform the operation.
Absence of leak hole may
operator. *Mixing
close the warning system for
of processed and 4 5 100
the user for a bad water
unprocessed ones.
pump
FPA &LPA (MAPL-F-QA-03)
 F-7.3.1-01

MAPL
FMEA No-
POTENTIAL FAILURE MODE AND EFFECT ANALYSIS ( PROCESS)
Rev No / Date
Part Name- WATER PUMP HOUSING Part No. D10369520A Rev.Details 0
Vehicle Model- AVL Customer M/S Escorts Kubota Process Responsibility- Mr. Mohit
Name Mr. Lovelaish Dassi Mr. Mohit Mr. Rahul Mr. Rajkumar
Core Team- Customer Approval (If Reqd.)
Sign

OCCURANC

OCCURANC
DETECTION

DETECTION
SEVERITY

SEVERITY
Process Function / Resp. &
Potential Failure Potential Cause(S) Current Process Control Current Process Control Recommended Target Action
Potential Effect of Failure CLASS RPN RPN

E
Mode Mechanism (S) of Failure Prevention Detection Action (S) Completion Taken
Requirement Date
FPA &LPA (MAPL-F-QA-03)
Op. to be done at start & end of
No. Drill Ø6 process & Inprocess
In case of oversize customer Only skilled & trained operators
6 Wrong tool selection 3 inspection (MAPL-F-QA-02) 5 90
dissatisfaction perform the operation
after every hour with PPG

Tool life monitoring sheet

Tool wear out 4 5 100
Leakage Hole In case of undersize Guidance given to Shop
50 5
drilling Customer dissatisfaction operator/WI supervisor
Only skilled & trained operators
Wrong tool selection 3 5 75
perform the operation

Drill location 52 *Not using the fixture Use of Fixture.

from mounting Customer dissatisfaction 7 *Part not clamped 4 Only trained & skilled 3 84
face not ok properly operators perform the operation.

FPA &LPA (MAPL-F-QA-03)

*Not using the fixture Use of Fixture. to be done at start & end of
Angle 25° Customer dissatisfaction 7 *Part not clamped 4 Only trained & skilled process & Inprocess 3 84
properly operators perform the operation. inspection (MAPL-F-QA-02)
after every hour with PPG

*Not using the fixture Use of Fixture.

Thru Hole Drill Function of leak hole failed
5 *Part not clamped 4 Only trained & skilled 3 60
Depth Customer dissatisfaction
properly operators perform the operation.

Presence of foreign particles

4 Nozzle may get choked 4 Daily cleaning of machine Inspection on regular basis 5 80
may affect the fitment assly
Improper Guidance given to Shop
60 Cleaning
cleaning operator/WI supervisor
Use of insufficient amount Work Instruction displayed
Parts may get rusted 5 4 Inspection on regular basis 5 100
of foreclean powder W.I./PR/3

Inspection standards not Skilled quality inspector

4 4 96
followed deployed

NG material dispatch to
Hole Locations customer and it may results 6 Inspection standard not Inspection standards and work
4 3 72
in customer complaint available. instructions displayed.

Final Inspection Report

MAPL-F-QA-10
 F-7.3.1-01

MAPL
FMEA No-
POTENTIAL FAILURE MODE AND EFFECT ANALYSIS ( PROCESS)
Rev No / Date
Part Name- WATER PUMP HOUSING Part No. D10369520A Rev.Details 0
Vehicle Model- AVL Customer M/S Escorts Kubota Process Responsibility- Mr. Mohit
Name Mr. Lovelaish Dassi Mr. Mohit Mr. Rahul Mr. Rajkumar
Core Team- Customer Approval (If Reqd.)
Sign

OCCURANC

OCCURANC
DETECTION

DETECTION
SEVERITY

SEVERITY
Process Function / Resp. &
Potential Failure NG material dispatch to Potential Cause(S) Current Process Control Current Process Control Recommended Target Action
Potential and
Effect of Failure CLASS RPN RPN

E
HoleMode
Locations customer it may results 6 Mechanism (S) of Failure Prevention Detection Action (S) Completion Taken
Requirement in customer complaint Date
Op.
No. Gauge issued and always
Unavailability of receiving
4 available at final inspection as 3 72
gauge
per requirement

Inspection standards not Skilled quality inspector Final Inspection Report

4 MAPL-F-QA-10 4 96
followed deployed

NG material may passed for

Mounting Holes the assembly which results Inspection standard not Inspection standards and work
6 4 4 96
dia. 9 (6 Holes) in line stoppage and time available. instructions displayed.
losses.

Gauge issued and always

Unavailability of receiving
4 available at final inspection as 4 96
gauge
per requirement

Boss Height 50 Only skilled & trained operators

Customer dissatisfaction 3 Oversize 5 6 90
may get rejected perform the operation Inform to Quality Quality
II Final Inspection
head Engineer
Sharp edges or burr may
present which results in Inspection standards and work
Chamfer 0.5x45° 3 Negligiency of operator 5 100% Visual Inspection 6 90
assembly problem because instructions displayed
of chamfer missing

Inspection standards not Skilled quality inspector

4 4 80
followed deployed

Taper Hole Dia Inspection standard not Inspection standards and work
Customer dissatisfaction 5 4 Final Inspection 4 80
10 available. instructions displayed.

Gauge issued and always

Unavailability of receiving
4 available at final inspection as 4 80
gauge
per requirement

Lack of lux level at

5 Lux level Monitoring sheet 6 90
inspection

Visual
Inspection Skilled quality inspector
(Operation Customer dissatisfaction 3 Unskilled inspector 4 100% Visual Inspection 4 48
deployed
missing, casting
defects etc.)

Inspection standard not Inspection standards and work

4 4 48
available. instructions displayed