Kumaran Industries Page 1 of 12

Process FMEA FMEA Number

PART NAME Traction transformer tank Prepared By
MODEL FMEA Date(Origin)

PROJECT CKG ad BQF tank

Process Potential Failure Mode Potential S Potential cause(s)/ O Current process controls D R Recommended
Function Effect(s) of e Mechanism of failure c e P Action
failure v c t N
u
r prevent Detect

Incoming material
not in size, rusty, delay in production 5 Vender not approved as per our 2 vender approval & Incoming material 2 36
inspection report
wrencle, pitted (OTD affected) norms. rating

Material received without order 2 order acceptance Incoming material 2 36

inspection report
sheets/Pipe/el acceptance.
bow/ Rod
(EN 10025-2
S355J2N, chemical & mechanical Application 5 Vender not approved as per our 2 vender approval & Incoming material 3 54 Incoming material laboretory testing will be
SS304L, properties not matched requirement not norms. rating inspection report
done every 3rd lot.(If the material is not co
EN 10204/3.1 MTC.
AW5754, AW meet. related with Manufacturer test report)
6082, Crack during bending

9 Material received without order 2 order acceptance Incoming material 2 36

inspection report
acceptance.

Welding filler not matched with delay in production 5 Vender not approved as per our 2 vender approval & Incoming material 2 20
inspection report
wire required specification (OTD affected) norms. rating
i.e.
EN ISO 14341-A-
G 42 4 M 3Si1, DIN EN Material received without order 2 order acceptance Incoming material 2 20
ISO 14343-A-G 23 12 L acceptance. inspection report
Si

chemical & mechanical Application 5 Vender not approved as per our 2 vender approval & Incoming material 2 20
inspection report
properties not matched requirement not norms. rating CE and DB certified
meet. material used. TC shall
be EN 10204/3.1

Shielding not matched with wps delay in production 4 Vender not approved as per our 2 vender approval & Gas TC review 2 16
gas requirement (OTD affected) norms. rating

Sunil Gupta K.M. Kumar .

Prepared by: Approved by: .
 Kumaran Industries Page 2 of 12

Process FMEA FMEA Number

PART NAME Traction transformer tank Prepared By
MODEL FMEA Date(Origin)

PROJECT CKG ad BQF tank

Process Potential Failure Mode Potential S Potential cause(s)/ O Current process controls D R Recommended
Function Effect(s) of e Mechanism of failure c e P Action
failure v c t N
Shielding not matched with wps delay in production u
gas requirement (OTD affected) r prevent Detect

4 Material received without order 2 order acceptance Gas TC review 2 20

acceptance.

Paint Wrong shade delay in production 5 Vender not approved as per our 2 vender approval & Incoming material 2 20
inspection report/TC
Wrong type of paint Self (OTD affected) norms. rating review , visual
life expired inspection of the
dram

Material received without order 2 order acceptance Incoming material 2 20

inspection report/TC
acceptance. review , visual
inspection of the
dram

Manufacturing Process

Component components not in size stop production flow 5 component cutting drawing is not as 2 controled cutting component 2 20
Preparation per requirement. plan/ drg. for inspection
components

Chamfer in Chamfer is not as per miner rework 10 compoment drawing is not as per 3 List of chamfer chamfer 2 60 Training need to provided to oparetor &
component(If drawing, Product fail during requirement, drawing is not component, inspection , inspector
Applicable ) chamfer is missing application (due to provided by design dept. Chamfer drawing Assy Inspection
wrong joint
prepretion)

surface Roughness is not as per OTD delay 10 drawing is not poperly read by 2 machining incoming 1 20
roughness of drawing, oil leak between oparetor. Mishandling, Poor surface instruction for sub inspection
machining sctrech mark on sealing surface protection supplier
component machined surface

Sunil Gupta K.M. Kumar .

Prepared by: Approved by: .
 Kumaran Industries Page 3 of 12

Process FMEA FMEA Number

PART NAME Traction transformer tank Prepared By
MODEL FMEA Date(Origin)

PROJECT CKG ad BQF tank

Process Potential Failure Mode Potential S Potential cause(s)/ O Current process controls D R Recommended
Function Effect(s) of e Mechanism of failure c e P Action
failure v c t N
u
r prevent Detect

Thread of improper thread , fitment problem at 10 wrong drill size used, wrong type tap 2 instruction for component 1 20
component NOGO gauges passed customer end, Oil used , thread gauges is not used. operator, inspection by
Go gauge not passed leakage, qualified
inspector.

fitup isnot as per major rework 3 Assembly done without fixture. 1 Assy instruction and Assy inspection 2 12
drawing fixture provided wrt drawing.
dimension out of
tolerance

Assembly small bosses major rework 3 Assembly done without fixture. 1 assembly in fixture, Assy inspection 2 12
/component assy at template use for wrt drawing.
wrong location bosses assy

Welding defects Major rework, 4 Improper gas selection, wrong 1 WPS provided welding 4 36
OTD affected electrode , worong parameter used, inspection/ plan
pre heating temperature is not as
per WPS

3 cleanliness of fusion face , rust mill 2 instruction provided Assy inspection 2 36

scale in weld joint by VT inspector

crack due to stress rework, production 3 Poor fit up 2 inspection before welding 2 36
delay welding inspection
Welding defects rework, production 4 improper cleanliness of fusion face 2 in process welding welding 2 36
(porosity ) delay inspection inspection

Sunil Gupta K.M. Kumar .

Weldingby:
Prepared Approved by: .
 Kumaran Industries Page 4 of 12

Process FMEA FMEA Number

PART NAME Traction transformer tank Prepared By
MODEL FMEA Date(Origin)

PROJECT CKG ad BQF tank

Process Potential Failure Mode Potential S Potential cause(s)/ O Current process controls D R Recommended
Function Effect(s) of e Mechanism of failure c e P Action
failure v c t N
u
r prevent Detect

welding defect cause by weld joint efficiency 4 instrument of welding machine is 2 Daily check list calibration 2 36
wrong parameter decrease, result fail not calibrated records,
during service

Welding
crack , lack of fusion weld joint efficiency 3 2 in process welding welding 2 36
decrease, result fail inspection inspection
during service

stop production flow rework, production 5 Surrounding area not covered 1 fully covered area welding 1 9
delay inspection
break in operation, rework, production 9 welding position not proper 2 welding positioner welding 2 36
welding defect delay provided inspection

Damage the weld joint efficiency 7 welding not done by suitable 2 welding inspection/ inspection 2 28
surroundings decrease result fail in welder(qualified for same only)/ approved welder list
during service WPS not followed

Less welding length reworks 4 weld plan not followed 2 welding inspection/ welding 2 24
plan inspection/ plan

Sunil Gupta K.M. Kumar .

Prepared by: Approved by: .
 Kumaran Industries Page 5 of 12

Process FMEA FMEA Number

PART NAME Traction transformer tank Prepared By
MODEL FMEA Date(Origin)

PROJECT CKG ad BQF tank

Process Potential Failure Mode Potential S Potential cause(s)/ O Current process controls D R Recommended
Function Effect(s) of e Mechanism of failure c e P Action
failure v c t N
u
r prevent Detect

Painting Painting defect(Orange major rework 3 surface cleanlliness/ roughness of 3 checked & 2 18
peal, flow marks, job is not as per SA2.5 & RA3.2 min. recorded
blisters….)

Paint ford cup viscosity is not in 3 checked & 2 18

between 30 - 40 sec. recorded
Painting/ drying done in open & 2 done in painting 2 12
uncontroled area. booth
Paint mixing ratio not proper. 2 Paint mixing ratio 2 12
clearly displeyed in
painting area &
measuring jar
available for
measure the paint
components

Sunil Gupta K.M. Kumar .

Prepared by: Approved by: .
 Kumaran Industries Page 6 of 12

Process FMEA FMEA Number

PART NAME Traction transformer tank Prepared By
MODEL FMEA Date(Origin)

PROJECT CKG ad BQF tank

Process Potential Failure Mode Potential S Potential cause(s)/ O Current process controls D R Recommended
Function Effect(s) of e Mechanism of failure c e P Action
failure v c t N
u
r prevent Detect

Fail in adhesion test reject in inspection 4 surface cleanlliness/ roughness of 3 shot blasting checked & 2 24
job is not as per SA2.5 & Ra3.2 min. inspection recorded

major rework 3
Low / higher DFT miner rework 2 Paint ford cup viscosity is not in 3 Inspection checked & 2 24
between 30 - 40 sec. recorded
reject in inspection 4 Alchometer is not calibrated 2 calibration status 3 24
marked on
instrument

Sunil Gupta K.M. Kumar .

Prepared by: Approved by: .
 doc. No.
KI/PFMEA/02 REV Page 7 of 12
03

KI/FMEA/02 R-0
Rohit Mathanker
1/11/2019

Responsibility Action
and target result
completion
date S O D R
e c e P
v c t N

Rohit 9 2 2 36
Mathanker

Sunil Gupta K.M. Kumar .

Prepared by: Approved by: .
 doc. No.
KI/PFMEA/02 REV Page 8 of 12
03

KI/FMEA/02 R-0
Rohit Mathanker
1/11/2019

Responsibility Action
and target result
completion
date S O D R
e c e P
v c t N

Rohit 10 1 2 20
Mathanker
completed by
15/10/2018

Sunil Gupta K.M. Kumar .

Prepared by: Approved by: .
 doc. No.
KI/PFMEA/02 REV Page 9 of 12
03

KI/FMEA/02 R-0
Rohit Mathanker
1/11/2019

Responsibility Action
and target result
completion
date S O D R
e c e P
v c t N

Sunil Gupta K.M. Kumar .

Prepared by: Approved by: .
 doc. No.
KI/PFMEA/02 REV Page 10 of 12
03

KI/FMEA/02 R-0
Rohit Mathanker
1/11/2019

Responsibility Action
and target result
completion
date S O D R
e c e P
v c t N

Sunil Gupta K.M. Kumar .

Prepared by: Approved by: .
 doc. No.
KI/PFMEA/02 REV Page 11 of 12
03

KI/FMEA/02 R-0
Rohit Mathanker
1/11/2019

Responsibility Action
and target result
completion
date S O D R
e c e P
v c t N

Sunil Gupta K.M. Kumar .

Prepared by: Approved by: .
 doc. No.
KI/PFMEA/02 REV Page 12 of 12
03

KI/FMEA/02 R-0
Rohit Mathanker
1/11/2019

Responsibility Action
and target result
completion
date S O D R
e c e P
v c t N

Sunil Gupta K.M. Kumar .

Prepared by: Approved by: .