Pfmea - Yxa Aac Panel

PROCESS FAILURE MODE AND EFFECT ANALYSIS
Planning & Preparation (STEP1)

Company Name: Motherson Automotive Technology & Engineering Subject: Injection Moulding Door Trim FR R/L PFMEA ID Number: PFMEA-MSIL-Y0M-01
Plant location: Manesar PFMEA Start Date: 25.08.21 Process Responsibility: Pardeep Kumar
Customer Name: MSIL PFMEA Revision Date: 30.09.21 Confidentiality Level: Business
Amit Suhag (Prod), Vinod Verma (QA), Mukesh Guleria (T/R), Rahul
Model Year/Program: Y0M / 2020 Cross Functional Team: Garg( QA), Bijendra Kumar(Prod), SP Yadav(Maint.), Pardeep Kumar
(PE), & Sandeep Sharma (QA)
CONTINUOUS
STRUCTURE ANALYSIS (STEP 2) FUNCTION ANALYSIS (STEP3) FAILURE ANALYSIS (STEP 4) RISK ANALYSIS (STEP 5) OPTIMIZATION (STEP 6)
IMPROVEMENT
Detection (D) of FC/FM
Special Characteristics
Occurrence (O) of FC
Filter Code (Optional)

1. Process Action
FMEA AP (Action
Severity (s) of FE
Special Product
Occurrence (O)
1. Function of the
Characteristics
Detection (D)
Item 2. Process Step 2. Function of the Process 3. Function of the Taken
Severity (s)
PFMEA AP
History/ Change 3. Process Work Process Item Respon Target
Remarks
ISSUE #
Priority)
System, Step and Product Process Work 2. Failure Mode (with Comple
Authorization (As Element (Function of 1. Failure Effects 3. Failure Causes (FC) of Current Detection Controls Prevention Detection sible Comple
Subsystem, Station No. and Characteristics Element and (FM) of the Current Prevention Control (PC) of FC Status pointer tion
Applicable) System, (FE) the Work Element (DC) of FC or FM Action Action Person' tion
Part Element Name of Process (Quantitative Value is Process Process Step to date
(optional) 4M Type Subsystem, Part s Name date
or Name of Step Optional) Characteristics evidenc
Element or process)
Process e
Injection Op. No. - 80A Man:-Jitter & In plant: To remove moisture from raw Man:- In plant:- Partial moisture in Less temperature set by 1. As per SMC-MSIL-YOM-01 FPA- QAD-F-71
Moulding of Pre-heating of raw Operator To make part from material. Jitter- To issue 1.Apperance NG (Silver raw material operator 2. Raw material check feeding check sheet
Door Trim FR material. Machine:- granules as per Product Characteristics. correct material & streak).-7 7 3. Skilled manpower. min-L2 5 6 M
R/L Dehumidifier engineering 1.Contamination in material qty. from store as per Ship to Plant:
Trolley specification & 2. moisture content in material work order, transport 1.Apperance NG (Silver
Material:- N/A aesthetic OK as per 3. Free from degradation to day bin & load in streak).-6
Less time set by operator 1. As per SMC-MSIL-YOM-01 FPA- QAD-F-71
Mother nature:- appearance limit dehumidifier End user:
2. Raw material check feeding check sheet
N/A sample Cleaning of 1.Apperance NG (Silver
7 3. Skilled manpower. min-L2 5 6 M
Ship to Plant dehumidifier streak).-3
(In-house assy): Operator-
To ensure proper To set the correct
fitment with mating temperature & time In plant:- Contamination in Air filter not cleaned. 1. PM check sheet (MNT-F-04L). FPA- QAD-F-71
part as per engineering as per material matrix 1.Apperance NG (Flow raw material
spec. To verify correct mark).-7 7 4 6 M
Appearance as per limit material loaded in Ship to Plant:
sample dehumidifier 1.Apperance NG (Flow
No abnormal noise Machine:- mark).-6
Ship to Plant Time duration-01~02 Dehumidifier not clean during 1. Raw material check feeding check sheet FPA- QAD-F-71
End user:
(Customer): hr raw material changer over 2. Skilled manpower. min-L2
1.Apperance NG (Flow
To ensure proper Temp.-70 +/- 10 0C Mark)-3 7 5 6 M
fitment with mating Cleaning air through
part as per engineering air filter
spec. Material:- N/A In plant:- De-gradation of raw Excess temp. set 1. As per SMC-MSIL-YOM-01 FPA- QAD-F-71
Appearance as per limit Mother nature:- N/A 1.Apperance NG (Flow material. 2. Raw material check feeding check sheet
sample mark).-7 7 3. Skilled manpower. min-L2 5 6 M
No abnormal noise Ship to Plant:
No harmfull flash at 1.Apperance NG (Flow
user touch points mark).-6 Excess time set 1. As per SMC-MSIL-YOM-01 FPA- QAD-F-71
End user: End user: 2. Raw material check feeding check sheet
Provide aesthetic right 1.Apperance NG (Flow 7 3. Skilled manpower. min-L2 5 6 M
appreance. Mark)-3
No abnormal noise
Op. No.80B Man:- 1 To inject plastic molten Man:- In-plant:- Short Molding Unskilled Operator Skilled manpower. min-L2 1. FPA- QAD-F-71
Perform Injection 1.Operator material by heating & pressing 1.Operator 1.Apperance NG.-7 2. Process parameter monitoring
Moulding operation 2.Shift in charge into a mould and then cooling a.To record the Ship to Plant ( In- every FML-04 hrs.
Machine:- Injection and solidifying under injection process parameter house) : 7 5 3. Rejection reconciliation QAD- 6 M
Moulding machine - pressure. per shift 1.Apperance NG. F-134/0.
81 (2400T) Part Characteristics Part. b.To report the 2.Fitment NG(Clip 4. 100% Visual Inspection at
-Mould a) Moulding part Weight abnormalities and Fitment, Gap NG)-6 station.
Material:-NA b)Part Geometry & holes as per follow stop call wait Ship to Plant
Mother nature:-NA drawing & ES. 2.Shift in charge (Customer) : 1.Barrel temp. less 1. PLC Controlled 1. FPA- QAD-F-71
C) Gap 3± 0.5 mm To set the process 1.Apperance NG ( Machine stop when temp. less) 2. Process parameter monitoring
D) Flush 1± 0.5 mm parameters as per 2. Fitment NG with every FML-04 hrs.
E) Color Delta E <1 SMC-MSIL-YOM-01 panel.-6 7 4 3. Rejection reconciliation QAD- 6 M
F) Gloss 2.5 ±0.5 Machine:- End user: F-134/0.
G) Grain texture Injection molding 1.Apperance NG 4. 100% Visual Inspection at
H) Dog house dimension at 09 machine to transform 2. Fitment NG with station.
Plcs. 4.9 ±0.1 mm raw material into panel.-4 2.Injection Pressure less 1. PLC Controlled. 1. FPA- QAD-F-71
i)Case pull handle Screw hole component 2.SMC-MSIL-YOM-01 (In case of any variation in parameter, 2. Process parameter monitoring
diameter at 02 plcs 4.0± 0.1 Material:- N/A machine will stop only). every FML-04 hrs.
J) Case pull handle snap lock Mother nature:- N/A 7 4 3. Rejection reconciliation QAD- 6 M
height 5.0± 0.1 Process F-134/0.
K) Pocket lock slot height Characteristics 4. 100% Visual Inspection at
C)No Aesthetic defects 1.Injection Time station.
1.Short Moulding. 2.Injection Speed 3. Nozzle leakage 1.Preventive maintenance of Machine (MNT-F-04L) 1. FPA- QAD-F-71
2.Silver Streak 3.Injection Pressure 2. Start-up check sheet ENG-WI-SU-1017 2. Process parameter monitoring
3.Burn mark. 4.Holding time every FML-04 hrs.
4.Sink Mark 5.Cushin 7 5 3. Rejection reconciliation QAD- 6 M
5.Shrinkage 6.Cooling time F-134/0.
6.Deformation 8.Charging time 4. 100% Visual Inspection at
7.Parting Line flashes 9.Nozzle station.
8.Air bubble Temperature 4. Less injection speed 1. PLC Controlled 1. FPA- QAD-F-71
8.Patch mark 10.Barrel 2.SMC-MSIL-YOM-01 (In case of any variation in parameter, 2. Process parameter monitoring
9.Watermark temperature machine will stop only) every FML-04 hrs.
7 4 3. Rejection reconciliation QAD- 6 M
10.Rib impression 11.Clamping tonnage
11.Ejector mark 12.Clamping force F-134/0.
12.oil mark less 4. 100% Visual Inspection at
13.colour NG 13.Pinworn out station.
5.Power failure 1.UPS back up 1. FPA- QAD-F-71
14 harmful flashes 14. Pin damage 2. Rejection reconciliation QAD-
15.Lifter worn out F-134/0.
16.HRTC not working 7 4 3. 100% Visual Inspection at 6 M
17.Mould temp. more station.
6. Machine stoppage 1. Auto disposal of start-up parts 03 nos. 1. FPA- QAD-F-71

(intermittently) 2. Rejection reconciliation QAD-
F-134/0.
7 4 3. 100% Visual Inspection at 6 M
station.
4. Raw material finish in 1. Sensor installed in hopper and alarm coming after min level 1. FPA- QAD-F-71
machine hopper of RM. 2. Rejection reconciliation QAD-
2. Material feeding Work instruction (ENG-WI-1025) F-134/0.
station.
5. Nozzle heater not working 1. PLC Controlled 1. FPA- QAD-F-71

( Machine stop when temp. less) 2. Process parameter monitoring
every FML-04 hrs.
F-134/0.
4. 100% Visual Inspection at
station.
6. Machine ring plunger worn 1. Preventive maintenance, check sheet MNT-F-04A. 1. FPA- QAD-F-71
out. 2. Rejection reconciliation QAD-
F-134/0.
station.
7. HRTC heater not working 1. PLC Controlled 1. FPA- QAD-F-71

( Machine stop when temp. less) 2. Process parameter monitoring
every FML-04 hrs.
F-134/0.
station.
8. Less mold temp. (Over 1. Chiller auto cut system below the set value 1. FPA- QAD-F-71
cooling) 2. Process parameter monitoring
every FML-04 hrs.
F-134/0.
station.
9.locking tonnage drop age 1. PLC controlled 1. FPA- QAD-F-71
(Machine stop in case of less locking tonnage) 2. Process parameter monitoring
every FML-04 hrs.
F-134/0.
station.
10. Sequential pin not working 1. Preventive maintenance of mold (MCO-TOM-CK-03) 1. FPA- QAD-F-71
2. Rejection reconciliation QAD-
F-134/0.
station.
11. Air venting block 1. Preventive maintenance of mold (MCO-TOM-CK-03) 1. FPA- QAD-F-71
2.Daily mold cleaning Check Sheet MTM-TDM-CK-19 2. Rejection reconciliation QAD-
F-134/0.
station.
12.Process parameter 1. Password locking system (Bio metric system) 1. FPA- QAD-F-71
tempering by operator 2. Process parameter monitoring
every FML-04 hrs.
F-134/0.
station.
13.Cushion variation 1. Preventive maintenance Check sheet MNT-F-04A 1. FPA- QAD-F-71
2. Auto generated Alarm mail for preventive maintenance. 2. Process parameter monitoring
every FML-04 hrs.
F-134/0.
station.
In-plant:- Flash (P/L, Hole) 1. Barrel temp. high 1. PLC Controlled 1. FPA- QAD-F-71
1.Apperance NG.-5 ( Machine stop when temp. less) 2. Process parameter monitoring
Ship to Plant ( In- every FML-04 hrs.
house) : 3. Rejection reconciliation QAD-
1.Apperance NG.-5 5 4 F-134/0. 6 L
Ship to Plant 4. 100% Visual Inspection at
(Customer) : station.
1.Apperance NG.-5
End user:
1.Apperance NG.-3 2. Injection speed high 1. PLC Controlled (In case of any variation in parameter, 1. FPA- QAD-F-71
machine will stop only). 2. Process parameter monitoring
2.SMC-MSIL-YOM-01 every FML-04 hrs.
5 4 F-134/0. 6 L
station.
3. Injection Pressure high 1. PLC Controlled (In case of any variation in parameter, 1. FPA- QAD-F-71
2. SMC-MSIL-YOM-01. every FML-04 hrs.
5 4 F-134/0. 6 L
station.
4. Holding Pressure high 1. PLC Controlled (In case of any variation in parameter, 1. FPA- QAD-F-71
2.SMC-MSIL-YOM-01 every FML-04 hrs.
5 4 F-134/0. 6 L
station.
5. Parting line wear out 1.Blue matching of mold after every Preventive maintenance 1. FPA- QAD-F-71
5 5 F-134/0. 6 L
station.
6.Pin matching not proper / 1.Blue matching of pin after every Preventive maintenance 1. FPA- QAD-F-71
Damage 2. Rejection reconciliation QAD-
5 (Hole) 5 F-134/0. 6 L
station.
7. Clamping tonnage less 1. PLC controlled 1. FPA- QAD-F-71

(Machine stop in case of less locking tonnage) 2. Process parameter monitoring
every FML-04 hrs.
5 4 F-134/0. 6 L
station.
In-plant:- Burn Mark 1. Air vent block 1. Preventive maintenance of mold (MCO-TOM-CK-03) 1. FPA- QAD-F-71
1.Apperance NG.-7 2.Daily mold cleaning Check Sheet-MTM-TDM-CK-19 2. Rejection reconciliation QAD-
Ship to Plant ( In- 7 5 F-134/0. 6 M
house) : 3. 100% Visual Inspection at
1.Apperance NG.-6 station.
Ship to Plant
(Customer) : 2. Injection speed high 1. PLC Controlled (In case of any variation in parameter, 1. FPA- QAD-F-71
1.Apperance NG.-6 machine will stop only). 2. Process parameter monitoring
End user: 2. As per SMC-MSIL-YOM-01 every FML-04 hrs.
1.Apperance NG.-4 3. Rejection reconciliation QAD-
7 4 6 M
F-134/0.
station.
3. Barrel temp. high 1. PLC controlled 1. FPA- QAD-F-71

(Machine stop in case of less locking tonnage). 2. Process parameter monitoring
every FML-04 hrs.
7 4 6 M
F-134/0.
station.
4. High temp. of mold 1. PLC controlled 1. FPA- QAD-F-71

(Machine stop in case of less locking tonnage). 2. Process parameter monitoring
every FML-04 hrs.
F-134/0.
station.
In-plant:- Flow mark 1. Barrel temp. high 1. PLC Controlled (In case of any variation in parameter, 1. FPA- QAD-F-71
Ship to Plant ( In- 2. As per SMC-MSIL-YOM-01 every FML-04 hrs.
7 4 6 M
1.Apperance NG.-6 F-134/0.
1.Apperance NG.-6
End user: 2. Barrel temp. low 1. PLC Controlled (In case of any variation in parameter, 1. FPA- QAD-F-71
2. As per SMC-MSIL-YOM-01 every FML-04 hrs.
7 4 6 M
F-134/0.
station.
3. HRTC temp. high 1. Alarming system available for HRS temperature. 1. FPA- QAD-F-71
2. Process parameter monitoring
every FML-04 hrs.
7 4 6 M
F-134/0.
station.
4. HRTC temp. low 1. PLC Controlled (In case of any variation in parameter, 1. FPA- QAD-F-71
7 4 6 M
F-134/0.
station.
5. Injection speed less 1. PLC Controlled (In case of any variation in parameter, 1. FPA- QAD-F-71
7 4 6 M
F-134/0.
station.
6. Injection speed high 1. PLC Controlled (In case of any variation in parameter, 1. FPA- QAD-F-71
7 4 6 M
F-134/0.
station.
In-plant:- Part weight less 1. Injection time less 1. PLC Controlled (In case of any variation in parameter, 1. FPA- QAD-F-71
1.Apperance NG. machine will stop only). 2. Process parameter monitoring
2. Fitment NG(Flush 2. As per SMC-MSIL-YOM-01 every FML-04 hrs.
NG).-7 7 4 3. Rejection reconciliation QAD- 6 M
Ship to Plant ( In- F-134/0.
house) 1.Apperance 4. 100% Visual Inspection at
NG station.
2. Fitment NG(Flush
NG).-7
NG).-7 2. Holding time less 1. PLC Controlled (In case of any variation in parameter, 1. FPA- QAD-F-71
Ship to Plant machine will stop only). 2. Process parameter monitoring
(Customer) : 2. As per SMC-MSIL-YOM-01 every FML-04 hrs.
1.Apperance NG 7 4 3. Rejection reconciliation QAD- 6 M
2. Fitment NG(Flush F-134/0.
NG).-7 4. 100% Visual Inspection at
End user: station.
1.Apperance NG.-3
3. Shot size less 1. PLC Controlled (In case of any variation in parameter, 1. FPA- QAD-F-71
machine will stop only). 2. Rejection reconciliation QAD-
2. As per SMC-MSIL-YOM-01 F-134/0.
7 4 6 M
station.
4. Nozzle leakage 1.Preventive maintenance of Machine (MNT-F-04L) 1. FPA- QAD-F-71

F-134/0.
7 5 6 M
station.
In-plant:- Part weight more 1. Injection time more 1. PLC Controlled (In case of any variation in parameter, 1. FPA- QAD-F-71
1.Apperance NG. machine will stop only). 2. Process parameter monitoring
2. Fitment NG(Flush 2. As per SMC-MSIL-YOM-01 every FML-04 hrs.
NG).-7 3. Rejection reconciliation QAD-
7 4 6 M
house) 1.Apperance 4. 100% Visual Inspection at
NG station.
2. Fitment NG(Flush
NG).-7 2. Holding time more 1. PLC Controlled (In case of any variation in parameter, 1. FPA- QAD-F-71
Ship to Plant machine will stop only). 2. Process parameter monitoring
(Customer) : 2. As per SMC-MSIL-YOM-01 every FML-04 hrs.
1.Apperance NG 3. Rejection reconciliation QAD-
2. Fitment NG(Flush 7 4 6 M
F-134/0.
NG).-7 4. 100% Visual Inspection at
End user: station.
1.Apperance NG.-3
3. Shot size more 1. PLC Controlled (In case of any variation in parameter, 1. FPA- QAD-F-71
7 4 6 M
F-134/0.
station.
In-plant:- Sink mark 1.Mould temp high 1. Alarming system available for mold temperature 1. FPA- QAD-F-71
Ship to Plant
(Customer) : 2. Holding time more 1. PLC Controlled (In case of any variation in parameter, 1. FPA- QAD-F-71
End user: 2. As per SMC-MSIL-YOM-01 every FML-04 hrs.
7 4 F-134/0. 6 M
station.
3. Shot size more 1. PLC Controlled (In case of any variation in parameter, 1. FPA- QAD-F-71
station.
4. Shot size less 1. PLC Controlled (In case of any variation in parameter, 1. FPA- QAD-F-71
station.
5. Less cooling time 1. PLC Controlled (In case of any variation in parameter, 1. FPA- QAD-F-71
7 4 F-134/0. 6 M
station.
6. Holding time less 1. PLC Controlled (In case of any variation in parameter, 1. FPA- QAD-F-71
F-134/0.
station.
7. Catching in rib 1.Preventive maintenance of Machine (MNT-F-04L) 1. FPA- QAD-F-71

F-134/0.
station.
8. Nozzle leakage 1.Preventive maintenance of Machine (MNT-F-04L) 1. FPA- QAD-F-71

F-134/0.
station.
In-plant:- Weld line 1. Injection time less 1. PLC Controlled (In case of any variation in parameter, 1. FPA- QAD-F-71
1.Apperance NG.-5 7 4 F-134/0. 6 M
1.Apperance NG.-5
End user:
1.Apperance NG.-2 2. Holding time less 1. PLC Controlled (In case of any variation in parameter, 1. FPA- QAD-F-71
7 4 F-134/0. 6 M
station.
3. Air vent block 1. Mold preventive maintenance check sheet(MCO-TOM-CK- 1. FPA- QAD-F-71
03). 2. Rejection reconciliation QAD-
2. Auto generated Alarm mail for preventive maintenance. F-134/0.
station.
4. Barrel temp. less 1. PLC Controlled (In case of any variation in parameter, 1. FPA- QAD-F-71
7 4 F-134/0. 6 M
station.
In-plant:- Shrink 1.Mould core cavity tempera 1-Process parameter verification as per SMC-MSIL-YOM-01 1. FPA- QAD-F-71
1.Apperance NG.-7 high 2. Rejection reconciliation QAD-
2. Fitment NG 7 5 F-134/0. 6 M
Ship to Plant ( In- 3. 100% Visual Inspection at
house) 1.Apperance station.
NG.-
1. PLC Controlled (In case of any variation in parameter, 1. FPA- QAD-F-71
2. Fitment NG.-6
Ship to Plant
(Customer) :
7 2.Less cooling time 4 3. Rejection reconciliation QAD- 6 M
1.Apperance NG
F-134/0.
2. Fitment NG.-6
End user:
station.
1.Apperance NG.-3
7 3.Less holding time 4 3. Rejection reconciliation QAD- 6 M
F-134/0.
station.

7 4.Less holding pressure 4 3. Rejection reconciliation QAD- 6 M
F-134/0.
station.
In-plant:- Silver Streaks 1. Moisture in material 1.Pre Heating as per RM requirement , manual control of 1. FPA- QAD-F-71
1.Apperance NG.-7 duration & automatic control of temperature in hopper . 2. Rejection reconciliation QAD-
Ship to Plant ( In- 7 2. Before loading RM bags condition is verified 5 F-134/0. 6 M
house) : 3. At the time of receiving of RM 3. 100% Visual Inspection at
Ship to Plant
(Customer) : 1.'Material degrade 1. PLC Controlled (In case of any variation in parameter, 1. FPA- QAD-F-71
1.Apperance NG.-6 machine will stop only). 2. Rejection reconciliation QAD-
End user: 2. As per SMC-MSIL-YOM-01 F-134/0.
7 4 6 M
1.Apperance NG.-3 3. 100% Visual Inspection at
station.
In-plant:- Rib impression 1.Less holding time 1. PLC Controlled (In case of any variation in parameter, 1. FPA- QAD-F-71
1.Apperance NG machine will stop only). 2. Process parameter monitoring
house) : 7 4 3. Rejection reconciliation QAD- 6 M
1.Apperance NG. F-134/0.
1.Apperance NG
End user: 2.Less injection speed 1. PLC Controlled (In case of any variation in parameter, 1. FPA- QAD-F-71
1.Apperance NG machine will stop only). 2. Process parameter monitoring
F-134/0.
station.
3.Catching in mold 1. Preventive maintenance Check sheet MNT-F-04L 1. FPA- QAD-F-71

2. Auto generated mail for preventive maintenance. 2. Rejection reconciliation QAD-
7 5 F-134/0. 6 M
station.
4. Lifter looseness 1. Preventive maintenance Check sheet MNT-F-04L 1. FPA- QAD-F-71

2. Auto generated mail for preventive maintenance. 2. Rejection reconciliation QAD-
7 5 F-134/0. 6 M
station.
5. Part over pack 1. As per SMC-MSIL-YOM-01 1. FPA- QAD-F-71

7 5 F-134/0. 6 M
station.
In-plant:- Air Bubble 1.More injection speed 1. PLC Controlled (Alarming system) 1. FPA- QAD-F-71
1.Apperance NG.-7 2. As per SMC-MSIL-YOM-01 2. Process parameter monitoring
Ship to Plant ( In- every FML-04 hrs.
1.Apperance NG.-6 7 4 F-134/0. 6 M
1.Apperance NG.-6
End user: 2.Mould temp high 1. Annunciator Alarming system 1. FPA- QAD-F-71
1.Apperance NG.-3 2. As per SMC-MSIL-YOM-01 2. Rejection reconciliation QAD-
7 3. Preventive maintenance Check sheet MNT-F-04L 4 F-134/0. 6 M
station.
3.Air vent block 1. Annunciator Alarming system 1. FPA- QAD-F-71

2. As per SMC-MSIL-YOM-01 2. Rejection reconciliation QAD-
station.
4. Condensation in core & 1. Annunciator Alarming system 1. FPA- QAD-F-71

cavity 2. As per SMC-MSIL-YOM-01 2. Rejection reconciliation QAD-
station.
In-plant:- Patch mark 1.Part over packed 1. PLC Controlled (In case of any variation in parameter, 1. FPA- QAD-F-71
Ship to Plant ( In- 7 2. As per SMC-MSIL-YOM-01 4 F-134/0. 6 M
Ship to Plant
(Customer) : 2. Sequential gate balancing 1. PLC Controlled (In case of any variation in parameter, 1. FPA- QAD-F-71
1.Apperance NG.-6 7 not proper machine will stop only). 4 2. Rejection reconciliation QAD- 6 M
End user: 2. As per SMC-MSIL-YOM-01 F-134/0.
1.Apperance NG.-3 3.High injection speed 1. PLC Controlled (In case of any variation in parameter, 1. FPA- QAD-F-71
7 4 6 M
F-134/0.
station.
In-plant:- Ejector pin mark 1.High ejection force 1. PLC Controlled (In case of any variation in parameter, 1. FPA- QAD-F-71
7 4 6 M
1.Apperance NG.-6 F-134/0.
1.Apperance NG.-7
End user: 2.Part over pack 1. PLC Controlled (In case of any variation in parameter, 1. FPA- QAD-F-71
station.
3. Ejector pin blunt 1. PLC Controlled (In case of any variation in parameter, 1. FPA- QAD-F-71
station.
4.Mould over heat 1.Alarming system available for mold temperature 1. FPA- QAD-F-71
F-134/0.
station.
In-plant:- Oil mark 1.Oil leakage from hose. 1. Tool preventive maintenance & auto mailer 1. FPA- QAD-F-71
1.Apperance NG.-5 (Core ) 2. Rejection reconciliation QAD-
Ship to Plant 4. Daily mold cleaning Check
(Customer) : 5 5 Sheet MTM-TDM-CK-19 6 L
1.Apperance NG.-5
End user:
1.Apperance NG.-3
In-plant:- White mark 1. Catching in Mold 1. Mold preventive maintenance check sheet(MCO-TOM-CK- 1. FPA- QAD-F-71
1.Apperance NG.-5 03). 2. Rejection reconciliation QAD-
Ship to Plant ( In- 2. Auto generated Alarm mail for preventive maintenance. F-134/0.
Ship to Plant
5 5 6 L
(Customer) :
1.Apperance NG.-5
End user:
1.Apperance NG.-3
In-plant:- Deformation 1.Mould core cavity 1. Annunciator Alarming system 1. FPA- QAD-F-71
1.Apperance NG.-7 temperature high 2. As per SMC-MSIL-YOM-01 2. Rejection reconciliation QAD-
2. Fitment NG(Gap).-7 3. Preventive maintenance of tool (MCO-TOM-CK-03). F-134/0.
Ship to Plant ( In- 3. 100% Visual Inspection at
house) station.
1.Apperance NG.
2. Fitment NG(Gap).-6 7 4 6 M
Ship to Plant
(Customer) :
1.Apperance NG
2. Fitment NG(Gap).-6
End user:
1.Apperance NG.-4 2.Cooling time less 1. PLC Controlled (In case of any variation in parameter, 1. FPA- QAD-F-71
7 4 6 M
F-134/0.
station.
In-plant:- Colour variation, 1. Improper purging 1. Purging as per ENG-WI-PRG-1024 1. FPA- QAD-F-71
1.Apperance NG.-7 Delta E >1 2. Skilled manpower. min-L2 2. Rejection reconciliation QAD-
Ship to Plant
(Customer) : 7 5 6 M
1.Apperance NG.-7
End user:
1.Apperance NG.-4
In-plant:- Water mark 1. Water leakage in mold 1. Start-up verification 1. FPA- QAD-F-71
Ship to Plant
5 5 6 L
(Customer) :
1.Apperance NG.-4
End user:
1.Apperance NG.-3
In-plant:- Wrong colour 1.Wrong raw material colour 1. Start-up verification 1. FPA- QAD-F-71
Ship to Plant 7 5 6 M
(Customer) :
1.Apperance NG.-7
End user:
1.Apperance NG.-4
In-plant:- Gap more then 1. Part packed less 1. Annunciator Alarming system 1. FPA- QAD-F-71
1.Apperance NG. Specification 2. As per SMC-MSIL-YOM-01 2. Rejection reconciliation QAD-
Ship to Plant ( In- 3.Parameter monitoring every 04 hrs-PRD-F-01 F-134/0.
7 4 6 M
1.Apperance NG station.
Ship to Plant
(Customer) : 2. Mold less cooling 1. Annunciator Alarming system Gap inspection , FPA- QAD-F-71
1.Apperance NG 2. As per SMC-MSIL-YOM-01
End user:
1.Apperance NG 7 4 6 M
3.High melting temp. of a barrel 1. Annunciator Alarming system Gap inspection , FPA- QAD-F-71
2. As per SMC-MSIL-YOM-01
3.Parameter monitoring every 04 hrs-PRD-F-01
7 4 6 M
4. Handling not as per Packaging 1.Work instruction-WI-DT-Y0M-01 Gap inspection , FPA- QAD-F-71
standard 2. Skilled manpower. min-L2
3.Pakaging standard
7 4 6 M
In-plant:- Flush more the 1. Part packed more 1. Annunciator Alarming system 1. Gap inspection , FPA- QAD-F-71
1.Apperance NG Specification 2. As per SMC-MSIL-YOM-01
Ship to Plant ( In- 3.Parameter monitoring every 04 hrs-PRD-F-01
7 4 6 M
house) :
1.Apperance NG
Ship to Plant
(Customer) : 2. Mold more cooling 1. Annunciator Alarming system Gap inspection , FPA- QAD-F-71
1.Apperance NG 2. As per SMC-MSIL-YOM-01
End user:
1.Apperance NG 7 4 6 M
3.High melting temp. of barrel 1. Annunciator Alarming system Gap inspection , FPA- QAD-F-71
2. As per SMC-MSIL-YOM-01
3.Parameter monitoring every 04 hrs-PRD-F-01
7 4 6 M
4. Handling not as per Packaging 1.Work instruction-WI-DT-Y0M-01 Gap inspection , FPA- QAD-F-71
standard 2. Skilled manpower. min-L2
3.Pakaging standard
7 4 6 M
In-plant:- Gloss more then 1.Mould over heat 1. Annunciator Alarming system 1. FPA- QAD-F-71
1.Apperance NG.-7 spec. 2. As per SMC-MSIL-YOM-01 2. Rejection reconciliation QAD-
Ship to Plant
(Customer) : 2. Material temp high 1. Annunciator Alarming system 1. FPA- QAD-F-71
1.Apperance NG.-7 2. As per SMC-MSIL-YOM-01 2. Rejection reconciliation QAD-
End user: 7 3.Parameter monitoring every 04 hrs-PRD-F-01 4 F-134/0. 6 M
1.Apperance NG.-4 3. 100% Visual Inspection at
station.
In-plant:- Dog house 1. Mold lifter worn out 1.Preventive maintenance of mould-MCO-TOM-CK-03) 1. FPA- QAD-F-71.
1.Fitment NG.-7 Dimension less then
Ship to Plant 4.9 + 0.1 mm
1.Fitment NG.-7 7 5 5 M
End user:
1.Noise.-4
In-plant:- Pocket Snap lock 1. Mold lifter worn out 1.Preventive maintenance of mould-MCO-TOM-CK-03) 1. FPA- QAD-F-71.
1.Fitment NG.-7 slot dimension less
Ship to Plant
End user:
1.Noise-4
In-plant:- Case pull HNDL 1. Mold pin worn out 1.Preventive maintenance of mould-MCO-TOM-CK-03) 1. FPA- QAD-F-71.
1.Fitment NG.-7 Hole dimension less
Ship to Plant (02 places)
End user:
1.Noise.-4
In-plant:- Case pull HNDL 1. Mold pin damage 1.Preventive maintenance of mould-MCO-TOM-CK-03) 1. FPA- QAD-F-71
1.Fitment NG.-7 area Hole block 2. Rejection reconciliation QAD-
Ship to Plant F-134/0.
1.Fitment NG.-7 7 5 3. 100% Visual Inspection at 6 M
End user: station.
1.Fitment NG.-4
In-plant:- Handle area Hole 1. Mold pin worn out 1.Preventive maintenance of mould-MCO-TOM-CK-03) 1. FPA- QAD-F-71.
1.Fitment NG.-7 dimension less
Ship to Plant
End user:
1.Noise.-4
In-plant:- Handle area Hole 1. Mold pin damage 1.Preventive maintenance of mould-MCO-TOM-CK-03) 1. FPA- QAD-F-71
1.Fitment NG block 2. Rejection reconciliation QAD-
1.Fitment NG 7 5 3. 100% Visual Inspection at 6 M
End user: station.
1.Fitment NG
Op. No.80C Man:-Operator 1.Cutting of gate point as per Man:- In-plant:- Gate point over cut 1.Untrained manpower Skilled manpower, min-L2 1. FPA- QAD-F-71
Gate cutting Machine:- Knife Work instruction To cut the gate point 1.Apperance NG.-7 (Deep cut) 2. Rejection reconciliation QAD-
Material:- N/A Machine:- Ship to Plant 7 5 F-134/0. 6 M
Mother nature:- To cut the gate point 1.Apperance NG.-6 3. 100% Visual Inspection at
N/A Material:- N/A End user: station.
Mother nature:- N/A 1.Apperance NG.-3 2. Knife not sharp Knife usage after sharpening 1. FPA- QAD-F-71
7 5 F-134/0. 6 M
station.
In-plant:- Gate point under cut 1.Untrained manpower Skilled manpower, min-L2 1. FPA- QAD-F-71
1.Apperance NG.-4 6 5 3. 100% Visual Inspection at 6 L
End user: station.
1.Apperance NG.-3
In-plant:- Gate point not cut 1.Untrained manpower Skilled manpower, min-L2 1. FPA- QAD-F-71
1.Apperance NG.-4 6 5 3. 100% Visual Inspection at 6 L
End user: station.
1.Apperance NG.-3
PROCESS FAILURE MODE AND EFFECT ANALYSIS
Planning & Preparation (STEP1)
Company Name: Nippon Audiotronix Ltd. Manesar Subject: YXA AUTO AC PANEL
Plant location: Manesar PFMEA Start Date: 11/17/2021 PFMEA ID Number:
Customer Name: MSIL PFMEA Revision Date: Process Responsibility: Pardeep Kumar
Cross Functional Team: Confidentiality Level:

Project Leader : Deepak Singh, Alok Sawhney, Preet Duggal
Core team : Deepak singh,Ashish rana,Devanand jha,Narender Talan,Vijender Business
Singh ,Abhishek,Amita,Jagdish,Ashish,Sumit kapoor,Manoj Yadav,Parminder,Neelesh,Ashutosh
Mishra
Model YXA AAC Panel

CONTINUOUS
STRUCTURE ANALYSIS (STEP 2) FUNCTION ANALYSIS (STEP3) FAILURE ANALYSIS (STEP 4) RISK ANALYSIS (STEP 5) OPTIMIZATION (STEP 6)
IMPROVEMENT
Detection (D) of FC/FM
Special Characteristics
Filter Code (Optional)
Occurrence (O) of FC
1. Process Action
FMEA AP (Action
Severity (s) of FE
Special Product
Occurrence (O)
1. Function of the 2. Function of the
Characteristics
Detection (D)
Item 3. Function of the Taken
Severity (s)
PFMEA AP
History/ Change 3. Process Work Process Item Process Step and Respon Target
Remarks
ISSUE #
Priority)
System, Process Work 2. Failure Mode Current Detection (with Comple
Authorization (As Element (Function of Product 1. Failure Effects 3. Failure Causes (FC) of Current Prevention Prevention Detection sible Comple
Subsystem, Station No. and Element and (FM) of the Controls (DC) of FC Status pointer tion
Applicable) System, Characteristics (FE) the Work Element Control (PC) of FC Action Action Person' tion
Part Element Name of Process Process Process Step or FM to date
(optional) 4M Type Subsystem, Part (Quantitative Value is s Name date
or Name of Step Characteristics evidenc
Element or process) Optional)
Process e
AUTO AC ASSEMBLY - 1 Man:-Assembly of In plant: TO ASSEMBLE PCB Man:- In-plant:- Dust on LCD Dust on line/working place 1)Prodcution under dust 1)Set up approval &
PANEL ASSY PCB SUB ASSY Child Parts : To make the sub WITH ,METAL COVER + Assy of Reflector with 1.Functioning NG.-8 control environment 100% visual inspection
Startup assembly for next LCD + REFLECTOR PCBA 2.Part Rejection 1) 100 % cleaning of LCD
checksheet/ visual station. Product Characteristics: Assy of LCD with Ship to Plant with air gun before assy
inspection of Ship to Plant 1)Assembly of reflector PCBA (Customer) :
previous steps/ NG (Customer): with PCBA Assy of Metal brackt 1.Functioning NG.-8
part indetification To ensure proper 2)Temperature sensor with PCBA End user: 8 2 6 M
Machine:- fitment with mating Pokayoke -Thermister Auto twisting of Metal 1.Functioning NG.-8
Assembly Fixture part as per engineering Resistance Functionality bracket legs
Material:- N/A spec. 2)LCD Appearance Machine:-
Mother nature:- Appearance as per limit 3)Assembly of LCD with To hold the part
Dust Free sample. Function as reflector during assy. & avoid
Enviornment per requirement. 4)LCD functioning damage /
In-plant:- Poor LCD handling on line LCD placement in tray with 1) Set up approval FPA
End user: 5)Assembly of metal appearance.
1.Functioning NG.-8 cavity to prevent 2) 100% visual inspection
Provide required cover & sub LCD assy Auto twisting of Metal
2.Part Rejection 8 damage/bending of LCD pin 2 on line 5 M
function & appearence 6)Twisting of Legs bracket legs.
Ship to Plant (Customer)
(Control AC functioning 7)Metal cover legs
:
grounding Material:- N/A LCD pin bend
1.Functioning NG.-8 LCD pin bend during assembly Manual control 100% LCD functioning
Mother nature:- Dust /damage
End user: check on fixture
Free Environment
1.Functioning NG.-8
8 2 5 M
In-plant:- Wrong orientation of Wrong orientation by operator. Poke-Yoke in fixture design 1) Wrong orientation of
1.Functioning NG.-8 PCBA on to fixture - PCBA cannot be wrong PCBA is detected at the
2.Part Rejection oriented stage itself
Ship to Plant (Customer) -Design Pokayoke 1) Set up approval FPA
: 8 1 2) 100% visual inspection 2 L
1.Functioning NG.-8 on line
End user:
1.Functioning NG.-8
In-plant:- Thermister Less Solering 100% Pokayoke to checxk 1.EOL Testing -100%
1.Functioning NG.-8 resitstance not as per Pin damage of the PCBA the resiatnce [POGO pin Temperature check at
2.Part Rejection specifications Compoenent missing [ 2 check the resistance ] EOL station
Ship to Plant (Customer) capacitor and Resistor ] 2.NG chute interlinkage
: 8 Shorting 1 2 L
1.Functioning NG.-8 POGO pin contact with PCBA
End user: pin [ Condition ]
1.Functioning NG.-8 3
2
1.Functioning NG.-8 reflector onto PCBA - Reflector cannot be wrong PCBA is detected at the
Ship to Plant (Customer) 1) Set up approval FPA
End user:
1.Functioning NG.-8
1.Functioning NG.-8 LCD with reflector - LCD cannot be wrong PCBA is detected at the
End user:
1.Functioning NG.-8
In-plant:- Incorrect assembly of Wrong orientation by operator. Poke-Yoke in fixture design 1) Wrong orientation of
1.Functioning NG.-8 LCD with reflector - LCD assembly cannot be PCBA is detected at the
2.Part Rejection wrongly placed . stage itself
End user:
1.Functioning NG.-8
In-plant:- LCD damage /crack Excess force applied on LCD Pneumatic assembly 100 % LCD functioning
1.Functioning NG.-8 during assy Multiple causes if applicable to fixture for Metal cover check- on station
2.Part Rejection be added -- operator assembly on to LCD sub
Ship to Plant (Customer) negligence, Machine assembly to prevent any
: 8 malfunction etc damage to LCD 2 2 L
1.Functioning NG.-8
End user:
1.Functioning NG.-8
In-plant:- Wrong orientation of Design proofing, sub lcd Wrong orientation is
1.Fitment NG.-8 metal cover with sub assy cannot be wrong detected at the stage
2.Part Rejection LCD assy oriented with metal cover itself
Ship to Plant (Customer) Set up approval
: 8 2 100% Visual inspection 2 L
1.Appearence NG.-8
End user:
1.Appearence NG.-8
In-plant:- LED not glow in the Power input not on Pin Start of shift in FPA 1.100% check at
1.Fitment NG.-8 PCBA LED Damage illumination tetsting
2.Part Rejection machine
Ship to Plant (Customer) 2.Check at IFC station
: 3.NG chute pokayoke for
1.Appearence NG.-8 8 2 2 discharge 2 L
End user:
1.Appearence NG.-8
In-plant:- Machine giving Tape missing 100% Camera Check for 1.100% NG chute
1.Functioning NG.-8 alaram when metal Tape tear apart the Tape interlinkage
2.Part Rejection cover asssembled Color Different
:
1.Functioning NG.-8 8 2 2 L
End user:
1.Functioning NG.-8 4
In-plant:- Improper twisting of Low air pressure of twisting jig. Pneumatic assembly fixture Digital pressure gauge is
1.Functioning NG.-8 legs of metal cover. for clinching the metal cover implemented to stop the
2.Part Rejection (Metal cover legs not legs on to sub (lcd + pcba process from functioning
Ship to Plant (Customer) grounded to PCBA assembly ) Pcba copper in case of Low
: copper pad's) pads pressure(PLC inter-
1.Functioning NG.-8 locking)
8 2 2 L
End user:
1.Functioning NG.-8
PCBA with Rubber Man:-Assembly of ASSEMBLY OF PCB Man:- In-plant:- Wrong orientation of Wrong orientation by operator. Poke-Yoke in fixture design 1) Wrong orientation of
Assy Child Parts SUB ASSY WITH Assy of PCB sub 1.Functioning NG.-8 PCBA on to fixture - PCBA cannot be wrong PCBA is detected at the
Machine:- RUBBER MAT assy with Rubber Mat 2.Part Rejection oriented stage itself
Assembly Fixture Product Characteristics: Machine:- Ship to Plant (Customer) 1) Set up approval FPA
Material:- N/A 1)Assembly of PCB SUB To hold the part : 2) 100% visual inspection
8 1 2 L
Mother nature:- Assy with rubber mat during assy. & avoid 1.Functioning NG.-8 on line
Dust Free damage / End user:
Enviornment appearance. 1.Functioning NG.-8
Material:- N/A
Mother nature:- Dust
Free Environment In-plant:-
1.Functioning NG.-8
2.Part Rejection
Excess force applied on LCD 100% Part presence 1) Set up approval FPA
: PCB Damage /Crack
8 Assembled withput Rubber Pokayoke available on the 2 2) 100% visual inspection 5 M
1.Functioning NG.-8 during assy
Mat station on line
End user:
1.Functioning NG.-8
In-plant:-
1.Functioning NG.-8
2.Part Rejection
Part presence sensor to 1.100% NG chute
: Rubber Mat not
8 Operation disturbed esnure the PCBA and 2 interlinkage to operation 2 L
1.Functioning NG.-8 pressed properly
Rubber mat miss
End user:
1.Functioning NG.-8
1 4
ASSEMBLY - 2 Man:-Assembly of ASSEMBLY OF PCB Man:- In-plant:- Temperture sensor

1)PCBA +RUBBER Child Parts SUB ASSY WITH Assy of PCB sub 1.Functioning NG.-8 damage during
MAT ASSLY. Machine:- RUBBER MAT assy with Gloss 2.Part Rejection assembly Design proofing,
2)MAIN ASSY Assembly Fixture Product Characteristics: Panel assy, Ship to Plant (Customer) temperature sensor is
Sticking or Touching of Temp 100% Visual inspection
Material:- N/A 1)Assembly of PCB SUB Machine:- : mounted at specified angle
8 Sensor with any movable part 1 100% Functional testing 5 L
Mother nature:- Assy with rubber mat To hold the part 1.Functioning NG.-8 due to which it will not
during assy post assembly
Dust Free during assy. & avoid End user: collide with gloss panel &
Enviornment damage / 1.Functioning NG.-8 will fit at the groove cavity
appearance. provided in the gloss panel.
Material:- N/A Assembly on fixture.
Mother nature:- Dust In-plant:-
Free Environment 1.Functioning NG.-8
2.Part Rejection
Rear cover,PCBA Part presence sensor to 1.100% NG chute
:
8 assy and Front cover Operation disturbed esnure the PCBA and 2 interlinkage to operation 2 L
1.Functioning NG.-8
not assembled Rubber mat miss
End user:
1.Functioning NG.-8
1 4
In-plant:-
1.Functioning NG.-8 1)Wrong rear cover
2.Part Rejection orientation is detected at
Wrong orientation of Design proofing rear cover
Ship to Plant (Customer) Working sequence not the stage itself
8 rear cover with gloss cannot be oriented wrong 1 2 L
: followed 2) Set up approval FPA
panel with gloss panel
1.Functioning NG.-8 3) 100% visual inspection
End user: on line
1.Functioning NG.-8
Man:-Assembly of TO ASSEMBLE SUB Man:-
ASSEMBLY 3 : Child Parts ASSY-3 WITH REAR Clip Mounting &
SCREWS + 4, Machine:- Assembly COVER+2 SCREW+4 Screwing of Assy Torque verification during
In-plant:- 1)Torque specification
PLASTIC CLIPS Fixture PLASTIC CLIPS:- Machine:- set up approval using
1.Functioning NG.-8 defined in WI
Electric screw driver Product Characteristics:- To hold the part 8 Excess torque of Screw Gun 2 torque meter 5 M
2.Part Rejection 2) Torque tampering
Material:- N/A ASSY OF CLIPS & during assy. & avoid 100% visual inspection of
Ship to Plant (Customer) protection
Mother nature:- Dust SCREW AS PER WI damage / Part
Free Enviornment appearance. : Part damage during
Torque 4.5~ 1.Functioning NG.-8 screwing
5.5kgf.cm End user:
1) Set up approval FPA
Screw qty = 02 nos. 1.Functioning NG.-8
2) Oversize screw
Screw Size 2.5 X 10 Functioning NG to be
Oversize screw not pass detected through
mm specified 8 Wrong Screw (Oversize) 2 2 L
through screw dispenser dispenser
Material:- N/A 2) 100% visual inspection
Mother nature:- Dust on line
Free Environment
In-plant:-
1.Loose Assy.
No screw guide provision in Screw guide provision is
: 5 Inclination of Screw 2 3) 100% visual inspection 5 L
fixture provided in fixture
1.Rattling Noise on line
End user:
1.Rattling Noise
In-plant:- 1)Torque specification
1.Loose Assy. defined in WI Torque verification during
Ship to Plant (Customer) 2) Torque tampering set up approval using
: 5 Less torque protection 2 torque meter 5 L
1.Rattling Noise 100% visual inspection of
End user: Part
1.Rattling Noise
In-plant:-
1.Loose Assy.
Ship to Plant (Customer) 1)Torque specification 1) Set up approval FPA
: 5 Screw under size defined in WI 2 2) 100% visual inspection 5 L
1.Rattling Noise 2)Screw as per BOM on line
End user:
1.Rattling Noise
Screw Loose
In-plant:-
1.Loose Assy.
Screw interlocking with
Gloss panel burring Hole tightening torque
(Small) mechanism established in
the assembly fixture
End user:
1.Rattling Noise
In-plant:-
1.Loose Assy.
Screw interlocking with
tightening torque
: 5 Gloss panel burring Hole (Big) 2 2) 100% visual inspection 3 L
mechanism established in
the assembly fixture
End user:
1.Rattling Noise
In-plant:-
1.Loose Assy. 1) Set up approval FPA
Screwing sequence
Ship to Plant (Customer) Screwing sequence not 2) 100% visual inspection
marking on fixture
: 5 Screw missing defined 2 on line 2 L
Srew miss Poka-Yoke
1.Rattling Noise Power Failure /Abnormal Stop 3)100% NG Chute
Defined
End user: 4
interlinkage
1.Rattling Noise
In-plant:-
1.Loose Assy.
Defined sequence of working Part clip presence sensor
: 5 Clip miss 2 2) 100% visual inspection 3 L
not followed avaialbe in assembly fixture
End user:
1.Rattling Noise
In-plant:- Clip loose mounted

1.Loose Assy.
Defined sequence of working
: 5 Snap fitment locking of clip 2 2) 100% visual inspection 5 L
not followed
End user:
1.Rattling Noise
In-plant:-
1.No Effect
Ship to Plant (Customer) Error proofing clip cannot 1) Set up approval FPA
: 8 Clip orientation wrong Clip orientation wrong be oriented in wrong 1 2) 100% visual inspection 3 L
1.Fittment Issue direction on line
End user:
1.No Effect
Man:-Loading of TO TEST THE Man:-
ILLUMINATION Assy in Testing ILLUMINATION OF Scanning of Bar In-plant:-
TESTING Machine Fixture AUTO AC PANEL Code. 1.No Effect
Machine:- Product Loading of Assy in Ship to Plant (Customer) 100% Testing
: Loss Of primary Defined sequence of assembly Bar code scan mechanism
Illumination Testing Characteristics:- testing fixture 8 AOI Testing skip 2 First part approval 4 L
Function & inspections not followed at AOI testing
Machine Illumination Testing of Machine:- In Station Auto Detection
Material:- N/A Part should be ok. To hold the part End user:
Mother nature:- Testing Ok Bar Code during testing & avoid 1.Loss Of primary
Dust Free Sticker should be paste damage / Function
Enviornment on Rear Cover appearance. In-plant:-
Material:- N/A 1.No Effect
Mother nature:- Dust Ship to Plant (Customer) Machine not giving
Free Environment Equipent validation with 100% Testing
: Loss Of primary correct results, NG Machine validation not done
8 master OK & NG sample at 2 First part approval 4 L
Function part flow to next with OK & NG sample
start of shift In Station Auto Detection
End user: process
1.Loss Of primary
Function
In-plant:-
1.Rejection
100% Testing
: Loss Of Secondary
7 Apperance not ok Wrong printing on panel 100 % AOI testing 2 First part approval 4L
Function
In Station Auto Detection
End user:
1.Loss Of Secondary
Function
In-plant:- Display flikkering/
1.Rejection lining on display 100% Testing
Ship to Plant (Customer) AOI testing, with error
First part approval
: Loss Of Secondary proofing , Defective LCD
7 LCD defective 2 In Station Auto Detection 2 L
Function with lining/display flikkering
100% NG chute
End user: will be rejected
interlinkage
1.Loss Of Secondary
Function
In-plant:-
1.Rejection
100% Testing
First part approval
: Loss Of Secondary LED light colour proofing , different colour
7 Different colour LED 2 In Station Auto Detection 2 L
Function different LED part will not pass
100% NG chute
End user: through testing machine
interlinkage
1.Loss Of Secondary
Function 4
In-plant:-
1.Rejection AOI testing, with error
Ship to Plant (Customer) proofing ,if luminance
LED light intensity 100% Testing
: Loss Of Secondary LED make is not as per
7 luminance value value is not as per the 2 First part approval 4 L
Function
low/high the specification In Station Auto Detection
End user: specification, part will
1.Loss Of Secondary be rejected.
Function
In-plant:-
1.Rejection
100% Testing
Ship to Plant (Customer) AOI testing, with error First part approval
: Loss Of Secondary LED defective(No
Function
7
light)
Defective LED proofing ,defective LED 2 In Station Auto Detection 2 L
part will be rejected 100% NG chute
End user:
interlinkage
1.Loss Of Secondary
4
Function
In-plant:- Light lekage

1.Rejection
Ship to Plant (Customer) AOI testing, with error 100% Testing
: Loss Of Secondary
Function
7 Defective LED proofing ,light leakage 2 First part approval 4 L
part will be rejected In Station Auto Detection
End user:
1.Loss Of Secondary
Function
In-plant:- Knobs & buttons

1.Rejection wrong placement
100% Testing
: Loss Of Secondary Wrong assembly of proofing, wrong
8 2 First part approval 4 L
Function buttons placement of knobs & In Station Auto Detection
End user: buttons will be verified
1.Loss Of Secondary
Function
Man:-Loading of TO TEST THE Man:- EOL Testing skip
AUTOMATED Assy in Testing FUNCTION OF AUTO AC Scanning of Bar In-plant:-
EOLTESTING(FUN Machine Fixture Bar PANEL Code. 1.No Effect
CTIONAL code pasting, NG Product Loading of Assy in Ship to Plant (Customer)
: Loss Of primary Defined sequence of assembly Bar code scan mechanism No scanning at
TESTING) part to be kept in red Characteristics:- testing fixture 8 2 4 L
Function & inspections not followed at AOI testing Pacakging station
bin Functional Testing of Part Machine:-
Machine:- EOL should be ok. To hold the part End user:
Tester Testing Ok Bar Code during testing & avoid 1.Loss Of primary
Material:- N/A Sticker should be paste damage / Function
Mother nature:- on Rear Cover appearance. In-plant:-
Dust Free Material:- N/A 1.No Effect
Enviornment Mother nature:- Dust Ship to Plant (Customer) 100% Testing
Machine not giving
Free Environment Equipent validation with First part approval
: Loss Of primary correct results, NG Machine validation not done
8 master OK & NG sample at 2 In Station Auto Detection 2 L
Function part flow to next with OK & NG sample
start of shift 100% NG chute
End user: process
interlinkage
1.Loss Of primary 4
Function
In-plant:-
1.Rejection
100% Testing
First part approval
: Loss Of Secondary
8 Software missing Software flashing missed 100 % AOI testing 2 In Station Auto Detection 2L
Function
100% NG chute
End user:
interlinkage
1.Loss Of Secondary 4
Function
In-plant:-
1.Rejection
100% Testing
First part approval
: Loss Of Primary Wrong software Incorrect software flashed
8 100 % AOI testing 2 In Station Auto Detection 2 L
Function version in IC 100% NG chute
End user:
interlinkage
1.Loss Of Primary
4
Function
In-plant:-
1.Rejection
100% Testing
First part approval
: Loss Of Primary Voltage out of
8 Test board failure 100 % AOI testing 2 In Station Auto Detection 4 L
Function specification 100% NG chute
End user:
interlinkage
1.Loss Of Primary
Function 4
100% Testing
First part approval
8 Test board failure 100 % AOI testing 2 In Station Auto Detection 4 L
In-plant:- 100% NG chute
1.Rejection interlinkage
Ship to Plant (Customer) 4
: Loss Of Primary
Dark current NG
Function
End user: Changing of pogo pin
1.Loss Of Primary Testing needle(pogo pin), as per the defined Pogo pin verification
Function having poor freqency capture in start up check
8 2 4 L
contact,oxidation or Preventive sheet
foreign bodies. maintenance of testing 100% Testing
jig as per plan
In-plant:-
1.Rejection
: Loss Of Secondary 100% Testing
8 Button function NG Test board failure 100% EOL testing 2 4 L
Function First part approval
End user:
1.Loss Of Secondary
Function
In-plant:-
1.Rejection
Ship to Plant (Customer) Scanner for post
Defined sequence of 100% visual
: Loss Of Secondary Label not pasted scanning of label
7 assembly & inspections 3 inspection 4 L
Function on to the part generated from EOL
End user: not followed First part approval
during packing
1.Loss Of Secondary
Function
In-plant:-
1.Rejection
Ship to Plant (Customer) Work instruction
Label not pasted as per 100% visual
: Loss Of Secondary Label pasted at displayed with pictorial
4 the defined position in 2 inspection 6 L
Function wrong location view on line showing
End user: Work standard First part approval
label position
1.Loss Of Secondary
Function
In-plant:-
1.Rejection Scanner for post
Ship to Plant (Customer) Label print not scanning of label 100% Testing
5 Printer setting error 3 4 L
: Visual Defect clear generated from EOL First part approval
End user: during packing
1.No Effect
In-plant:-
1.Rejection 100% PCBA QR code
Ship to Plant (Customer) scan to print & paste
: Loss Of Secondary PCBA QR code scan to the sticker on ac panel 100% Testing
7 No interlinking 3 4 L
Function print not done unit for interlinkage of First part approval
End user: EOL passed & PCBA
1.Loss Of Secondary
Function
QR code sticker
Man:-Loading of
Assy in Testing
Machine Fixture Bar
code Scanning , NG
part to be kept in
Man -Scanning the In-plant:-
NG Chute
Bar code 1.Rejection
Machine:- IFC
Follow WI and check Ship to Plant (Customer) 100% Function of
testing IFC failure [Button or
To check the Button and the button and : Loss Of Secondary Button stuck /Toggle NG chute interlinkage
IFC Station Material:- N/A 8 Toggle Movement Button and Toggle 2 2 L
Mother nature:- Dust
Toggle working Toggle working Function
abnormal ] Break with Machine
Machine -To check End user: check
Free Enviornment
the working and 1.Loss Of Secondary
alignment with part Function
Man :Pacakaging of In-plant:-

the part as per WI 1.Rejection
To esnure no Man -Visually check Barcode in reverse
: Loss Of Secondary 100% Barcode and NG chute interlinkage
Pakaging station torn,Dent,scratch on the and Barcode 8 direction Torn/Repeated 2 2 L
part scanning of the part
Function
Barcode repeated Repeat check at station with Machine
End user:
1.Loss Of Secondary 4
Function
3
NG chute added at stations [PCBA assy,Rubber Assy,Front Panel Assy ,EOL,IFC station
Neelesh Ashutosh
5 7/18/2022 4 and Printing ] Customer Reuirement
Thermistor Sensor Pogo Pin check
Neelesh Ashutosh
4 7/14/2022 3 Inhouse Concern
LED glow failure mode-Inhouse Concern
Neelesh Ashutosh
3 6/18/2022 2 Inhouse Concern
PCBA +Rubber Assy & Front Cover assy Part presence Pokayoke added
Neelesh Ashutosh
2 5/26/2022 1 Manual to pnumatics
Initially Release
1 26.09.2022 0 Line Setup Neelesh Ashutosh
S.No Revision date Rev No Revision detail Reason of revision Prepared By Approved by
PWR MNL
83720- 83710- 83720- 83710- 83720- 83710-

53T20* 53T20* 53T10* 53T10* 53T00* 53T00*
Assembly Part
No.
LH RH LH RH LH RH
BILL OF MATERIAL
P/W ADJUST MIRROR
6475- DOM. 25550-DOM. 142975 DOM.

14857- EXP. 3242- EXP.- 12054- EXP.-
(LHD+RHD) (LHD+RHD) (LHD+RHD)
ANNUAL
VOLUME
Total 21332Total 28792Total 155029
Total - 205153
VAIRENT MATRIX PART DETAIL RAW MATERIAL PART

WEIGHT
ITEM Remark
QTY PART NO. PART NAME Annual Volume Process MATERIAL GRADE Colour SUPPLIER Weight
9 9 9 9 9 9 9 09409-10321 CLIP FR DOOR TRIM 3692754 BOP POM NATURAL NIFCO Existing
7 7 7 7 7 7 8 83716-68K0* PAD DOOR TRIM 2872142 BOP URETHENE FOAM URETHENE FOAM SSP, GURGAON Existing
35±5 Kg /m3 35±5 Kg /m3
2 2 2 2 2 2 7 03541-0410A SCREW. FR DOOR TRIM 820612 BOP SAE-1010 SAE-1010 SUPER FINE Existing
1 1 1 1 1 1 6 83755-62S0* PAD RGLTR HANDLE 410306 BOP PE FOAM (70±10kg/m3 SSP, GURGAON I.D. 20mm
70±10 Kg /m3
EE-1010 O.D. 45mm
1 1 1 1 1 1 5 83756-53T0* SILENCER DOOR TRIM 410306 BOP NITTO DENKO EE-1010 BLACK SSP, GURGAON W8*H8*L110
1 1 1 83726-53T0* PAD FR DOOR TRIM L 205153 BOP MINDA KYORUKU

Bawal
4
1 1 1 83716-53T0* PAD FR DOOR TRIM R 205153 BOP MINDA KYORUKU
Bawal
1 1 1 83725-53T0* CASE DR INS PULL HANDLE L 205153
3 IM PPDTN3 BA65130F QBQ MACHINO ,Gurgaon New
1 1 1 83715-53T0* CASE DR INS PULL HANDLE R 205153
1 1 1 83724-53T0* POCKET FR DOOR TRIM L 205153

2 IM PPSN3 BA65122F QBQ MACHINO ,Gurgaon New
1 1 1 83714-53T0* POCKET FR DOOR TRIM R 205153
1 83721-53T2* TRIM FR DOOR L 21332

IM PPDTN3 BA65130F QBQ MACHINO ,Gurgaon New
1 83711-53T2* TRIM FR DOOR R 21332
1 83721-53T1* TRIM FR DOOR L 28792

1 IM PPDTN3 BA65130F QBQ MACHINO ,Gurgaon New
1 83711-53T1* TRIM FR DOOR R 28792
1 83721-53T0* TRIM FR DOOR L 155029

IM PPDTN3 BA65130F QBQ MACHINO ,Gurgaon New
1 83711-53T0* TRIM FR DOOR R 155029
Process General Evaluation Criteria Severity (S)
Potential Failure Effects rated according to the criteria below
Impact to Ship to plant (When Impact to End User (When

S Effect Impact to Your Plant
Known) Known)
Failure may result in Affects safe operation of the

Failure may result in health
health and/or safety vehicle and/ or other
and/or safety risk for the
10 risk for the vehicles, the health of driver
manufacturing or the
manufacturing or the or passenger(s) or road users
assembly worker
High assembly worker or pedestrians
failure may result in in-

failure may result in in-plant noncompliance with
9 plant regulatory non-
regulatory non-compliance regulations
compliance
Line shutdown grater than full

production shift; stopped
Loss of primary vehicle
100% of production shipment possible; field repair
function necessary for normal
8 run affected may have or replacement required
driving during expected
to be scrapped. (assembly to end user) other
service life.
than for regulatory non
compliance.
Moderatel
y high
Product may have to

Line shutdown from one hour
be sorted and a
up to full production shift;
portion( less than Degradation of primary
stopped shipment possible;
100%) scrapped; vehicle function necessary for
7 field repair or replacement
deviation from primary normal driving during
required (assemble to end
process; decreased line expected service life.
user) other than for regulatory
speed or added
non-compliance
manpower
100% of the
production run may Loss of secondary vehicle
6 Line shutdown up to one hour
have to reworked function
offline and accepted
Moderatel
y low
Less than 100% of product
A portion of production
affected; strong possibility for
run may have to be Degradation of secondary
5 additional defective product;
Moderatel reworked offline and vehicle function
sort required; no line
y low accepted
shutdown
100% of production Defective product triggers

Very objectionable
run may have to be significant reaction plan;
4 appearance, sound, vibration,
reworked in station additional defective product
harshness, or haptics,
before it is processed not likely; sort not required
a portion of production Defective product triggers

Moderately objectionable
run may have to be minor reaction plan;
3 appearance, sound, vibration,
reworked in station additional defective product
harshness, or haptics,
before it is processed not likely; sort not required
Low
Defective product triggers no

Slight inconvenience to reaction plan; additional Slightly objectionable
2 process, operation or defective product not likely; appearance, sound, vibration,
operator sort not required; requires harshness, or haptics,
feedback to supplier
No discernible effect or no
1 Very Low No discerning effect No discernible effect
effect
(S)
Blank Until
filled in by
user
Corporate or
product Line
Examples
Occurrence potential (O) for the process
Potential Failure Causes rated according to the criteria below. Consider Prevention Controls when
determining the best Occurrence estimate, Occurrence is predictive qualitative rating made at the
time of evaluation and may not reflect the actual occurrence. The occurrence rating number is relative
rating within the scope of FMEA (process being evaluated). For Prevention Controls with multiple
Occurrence Ratings, use the rating that best reflects the robustness of the control.
Prediction
of failure
O Type of controls Prevention controls
cause
occurring
Extremely
10 None No prevention control.
High
9 Prevention control will have little effect in preventing failure
Very high Behavioral
8 cause
7 Prevention control somewhat effective in preventing failure
High
6 cause
5 Behavioral or technical
Moderate Prevention control are effective in preventing failure cause
4
3 Low Best practices: Prevention control are highly effective in preventing failure
2 Very Low Behavioral or technical cause
Prevention control are extremely effective in preventing

failure cause from occurring due to design ( e.g. part
Extremely
1 Technical geometry) or process (e.g. fixture of tooling design). Intent of
Low
prevention controls- failure mode cannot be physically
produced due to the failure cause.
Blank Until
filled in by
user
Corporate or
product Line
Examples
Detection potential (D) for the validation of the process design
Detection control rated according to detection method, maturity and opportunity for detection
Ability to
D Detection method maturity
detect
No testing or inspection method has been

10
established or is known
Very Low
It is unlikely that the testing or inspection method

9
will detect the failure mode
8
Testing or inspection method has not been proven to
be effective and reliable (e.g. plant has little or no
Low experience with method, gauge, R&R, results,
marginals, or comparable process, or this application,
7 etc.)
6
Test or inspection method has been proven to be
effective and reliable (e.g. plant has experience with
Moderate
method, gauge, R&R, results are acceptable on
comparable process or this application, etc.)
5
System has been proven to be effective and reliable

(e.g. Plant has experience with method or identical
process or this application), gauge R&R results are
acceptable, etc.
High
System has been proven to be effective and reliable
(e.g. Plant has experience with method or identical
process or this application), gauge R&R results are
acceptable, etc.
High
Detection method has been proven effective and

2 reliable (e.g.. Plant has experience with method,
error proofing verification, etc.)
Failure mode cannot be physically produced as design or process or detection method proven to always dete
1 Very high
failure mode or failure cause
D) for the validation of the process design
Blank Until
tection method, maturity and opportunity for detection filled in by
user
Corporate
or product
Opportunity for detection
Line
Examples
the failure mode will not or cannot be detected
The failure mode is not easily detected through random or

sporadic audits
human inspection (visual, tactile, audible), or use of manual
gauging ( attribute or variable) that should detect the failure
mode or failure cause
Machine based detection ( automated or semi automated

with notification by light, buzzer, etc.) or use of inspection
equipment such as co-ordinate measuring machine that
should detect failure mode or failure cause
human inspection (visual, tactile, audible), or use of manual

gauging ( attribute or variable) that will detect the failure
mode or failure cause (including product sample checks)
Machine based detection (semi automated with notification

by light, buzzer, etc.), or use of inspection equipment such as
co-ordinate measuring machine that will detect failure mode
or failure cause (including product sample checks)
Machine based automated detection method that will detect

failure mode downstream, prevent further processing or
system will identify the product as discrepant and allow it to
move automatically move forward in the process until the
designated reject unload area. Discrepant product will be
controlled by a robust system that will prevent outflow of
product form the facility
Machine based automated detection method that will detect
failure mode in-station, prevent further processing or system
will identify the product as discrepant and allow it to move
automatically move forward in the process until the
designated reject unload area. Discrepant product will be
controlled by a robust system that will prevent outflow of
product form the facility
Machine based detection method that will detect the cause

and prevent the failure mode (discrepant part) from being
produced
ed as design or process or detection method proven to always detect the

failure mode or failure cause
Action Priority (AP) for DFMEA and PFMEA
Action Priority is based on combinations of Severity, Occurrence, and Detection ratings in order to Blank until
prioritize actions for risk reduction filled in by
user
Prediction of ACTION
Effect S Failure Cause O Ability to Detect D PRIORITY Comments
Occuring (AP)
Low - Very Low 7-10 H
Moderate 5-6 H
Very High 8-10
High 2-4 H
Very High 1 H
Moderate 5-6 H
High 6-7
High 2-4 H
Very High 1 H
Product or
9-10 Low - Very Low 7-10 H
Plant Effect
Very high Moderate 5-6 H
Moderate 4-5
High 2-4 H
Very High 1 M
Moderate 5-6 M
Low 2-3
High 2-4 L
Very High 1 L
Very Low 1 Very High - Very Low 1-10 L
Moderate 5-6 H
Very High 8-10
High 2-4 H
Very High 1 H
Moderate 5-6 H
High 6-7
High 2-4 H
Very High 1 M
Product or
7-8 Low - Very Low 7-10 H
Plant Effect
High Moderate 5-6 M
Moderate 4-5
High 2-4 M
Very High 1 M
Low - Very Low 7-10 M
Moderate 5-6 M
Low 2-3
High 2-4 L
Very High 1 L

Moderate 5-6 H
Very High 8-10
High 2-4 M
Very High 1 M
Moderate 5-6 M
High 6-7
High 2-4 M
Very High 1 L
Product or Low - Very Low 7-10 M
Plant Effect 4-6
Moderate 5-6 L
Moderate Moderate 4-5
High 2-4 L
Very High 1 L
Low - Very Low 7-10 L
Moderate 5-6 L
Low 2-3
High 2-4 L
Very High 1 L

Moderate 5-6 M
Very High 8-10
High 2-4 L
Very High 1 L
Moderate 5-6 L
High 6-7
High 2-4 L
Very High 1 L
Product or Low - Very Low 7-10 L
Plant Effect 7-8
Moderate 5-6 L
Low Moderate 4-5
High 2-4 L
Very High 1 L
Moderate 5-6 L
Low 2-3
Product or
Plant Effect 7-8
Low
Low 2-3
High 2-4 L
Very High 1 L
No discernible 1 Very low - Very 1-10 Very High - Very Low 1-10 L
Effect high

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PROCESS FAILURE MODE AND EFFECT ANALYSIS

Planning & Preparation (STEP1)

Detection (D) of FC/FM

Filter Code (Optional)

6. Machine stoppage 1. Auto disposal of start-up parts 03 nos. 1. FPA- QAD-F-71

5. Nozzle heater not working 1. PLC Controlled 1. FPA- QAD-F-71

7. HRTC heater not working 1. PLC Controlled 1. FPA- QAD-F-71

7. Clamping tonnage less 1. PLC controlled 1. FPA- QAD-F-71

3. Barrel temp. high 1. PLC controlled 1. FPA- QAD-F-71

4. High temp. of mold 1. PLC controlled 1. FPA- QAD-F-71

4. Nozzle leakage 1.Preventive maintenance of Machine (MNT-F-04L) 1. FPA- QAD-F-71

7. Catching in rib 1.Preventive maintenance of Machine (MNT-F-04L) 1. FPA- QAD-F-71

8. Nozzle leakage 1.Preventive maintenance of Machine (MNT-F-04L) 1. FPA- QAD-F-71

1. PLC Controlled (In case of any variation in parameter, 1. FPA- QAD-F-71

3.Catching in mold 1. Preventive maintenance Check sheet MNT-F-04L 1. FPA- QAD-F-71

4. Lifter looseness 1. Preventive maintenance Check sheet MNT-F-04L 1. FPA- QAD-F-71

5. Part over pack 1. As per SMC-MSIL-YOM-01 1. FPA- QAD-F-71

3.Air vent block 1. Annunciator Alarming system 1. FPA- QAD-F-71

4. Condensation in core & 1. Annunciator Alarming system 1. FPA- QAD-F-71

Cross Functional Team: Confidentiality Level:

Model YXA AAC Panel

Detection (D) of FC/FM

ASSEMBLY - 2 Man:-Assembly of ASSEMBLY OF PCB Man:- In-plant:- Temperture sensor

In-plant:- Clip loose mounted

In-plant:- Light lekage

In-plant:- Knobs & buttons

Man :Pacakaging of In-plant:-

83720- 83710- 83720- 83710- 83720- 83710-

6475- DOM. 25550-DOM. 142975 DOM.

VAIRENT MATRIX PART DETAIL RAW MATERIAL PART

1 1 1 83726-53T0* PAD FR DOOR TRIM L 205153 BOP MINDA KYORUKU

1 1 1 83724-53T0* POCKET FR DOOR TRIM L 205153

1 83721-53T2* TRIM FR DOOR L 21332

1 83721-53T1* TRIM FR DOOR L 28792

1 83721-53T0* TRIM FR DOOR L 155029

Potential Failure Effects rated according to the criteria below

Impact to Ship to plant (When Impact to End User (When

Failure may result in Affects safe operation of the

failure may result in in-

Line shutdown grater than full

Product may have to

100% of production Defective product triggers

a portion of production Defective product triggers

Defective product triggers no

Prevention control are extremely effective in preventing

No testing or inspection method has been

It is unlikely that the testing or inspection method

System has been proven to be effective and reliable

Detection method has been proven effective and

the failure mode will not or cannot be detected

The failure mode is not easily detected through random or

Machine based detection ( automated or semi automated

human inspection (visual, tactile, audible), or use of manual

Machine based detection (semi automated with notification

Machine based automated detection method that will detect

Machine based detection method that will detect the cause

ed as design or process or detection method proven to always detect the

Low - Very Low 7-10 H

Low - Very Low 7-10 M

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