PROCESS (Potential) FAILURE MODE & EFFECTS ANALYSIS Page: 01 of 01

Part Description : BLADE TRIM /BR THERMAL Process Description & Responsibility:- Anirudh Mohta FRMATE Number : SMPL/QA/FMEA/01

Part No.: FAMILY COMMON FOR ALL ECN No./Date: - Prepared By- Dharmender Yadav

Core Team: Anirudh Mohta ,Dharmender Yadav , Pramendra kr. Baiitha ,Sumeer Singh ,Tapan
Model : FANS OR ELECTRIC APPLIANCES kumar das & Damodar Sharma . Next Review Date: 10.03.2024

FMEA Date (Revision): 00

s Action Results
D
e Potential Cause O

CLASS
E Responsibilit
v (s) / Mechanism (s) C Current R
Potential Failure Potential Effect (s) Current Preventive T y & Target

DETECT
PFD Stage Process Function /Requirement r of Failure C Detective P Recommended Action (s)

OCCUR
Completion Actio

R P N
Mode of Failure Controls E

SEV.
i (Consider C&E U Controls N n
C Date
t Matrix) R Taken
T
y

visuals inspection
on the bags /Ink
Raw material
container as per the
/Printing Ink not as 7 M wrong material supply …................. 1 6 42
invoice details while
per invoice
unloading the
Next operation - material.
Difficult to process the
material
Assly.- part Get rejected
in the assly.
Customer-Fit & function
issue at custmer .
End Customer
-field failure.

10
Incoming /verification of visuals inspection
raw material Raw material/Ink on the bags as per
wrong grade /shade Material Testing report /Shade
not as per 7 M 1 the invoice details 6 42
supply trial done on sampling basis
specification while unloading the
material

visuals inspection
Raw material
lot No/Batch No.not on the bags as per
without
7 M mentioned on raw ….................. 1 the invoice details 6 42
identification&
material bags while unloading the
tracebility
material

Next operation -
Difficult to process the
A.incoming
material mixture of coarse & inspection of the raw
Assly.- part get rejected fine granules material.
Contaminated raw due to poor asthetic
4 Mi /foreign particles …................... 3 B.Inspection during 4 48
material Customer- part get
/moisture in raw the material usage .
rejected due to poor
material C.Part inspection
asthetic .
after moulding
End Customer -
Dissatisfaction

Next operation -
Difficult to handle the Raw material
material Improper laoding of checked during
Damged bags/Ink Training to given to respective
Assly.- ….... 5 Mi the material /Transist 3 unloading at the 4 60
container employee
Customer-…...... damage time of reciept for
End Customer - the damage .
…...

Next operation - Mi
Difficult to find last lot of
the material .
Storage without lack of knowlwdge colour coding
Assly.- ….... 5 displayed FIFO Standard 3 4 60
FIFO /unskilled followed batchwise
Customer-…......
End Customer -
…...
 PROCESS (Potential) FAILURE MODE & EFFECTS ANALYSIS Page: 01 of 01

Part Description : BLADE TRIM /BR THERMAL Process Description & Responsibility:- Anirudh Mohta FRMATE Number : SMPL/QA/FMEA/01

Part No.: FAMILY COMMON FOR ALL ECN No./Date: - Prepared By- Dharmender Yadav

Core Team: Anirudh Mohta ,Dharmender Yadav , Pramendra kr. Baiitha ,Sumeer Singh ,Tapan
Model : FANS OR ELECTRIC APPLIANCES kumar das & Damodar Sharma . Next Review Date: 10.03.2024
Next operation -
Difficult to find last lot of
the material . FMEA Date (Revision): 00
Storage without lack of knowlwdge colour coding
Assly.- ….... 5 displayed FIFO Standard 3 4 60
FIFO /unskilled followed batchwise
Customer-…......
End Customer -
…... Mi
20 Storage of Raw Material

Next operation -
Difficult to process the
material
Assly.- part may get
Ink Storage not rejected due to shade
Neglegency of store instruction to be given to Cross check &
allowed in open dry variation . 5 Mi 3 4 60
inchrage supervisor & displayed WI. ensure visually .
environment Customer- part may get
rejected due to shade
variation .
End Customer -
dissatisfaction

identification Next operation - 100% Visual

problem to issuing 6 M 2 4 48
missing Inspection
material .
Assly.- .......
operator Negligency On job training & WI Provided
Customer- functio
failure .
100% Visual
wrong Identifictaion End Customer - 6 M 2 4 48
Disatisfaction Inspection

Next operation - ….......

Assly.- ….... cross -check the
Material palced at Customer-Functional material/ bin
6 M lots are not identified 2 7 84
wrong location failure. identification before
30 Transfer raw material End Customer - issuing .
Dissatisfaction

On job training & WI Provided &

Next operation - colour coding provided
improper material may
lead to functional
/manufacturing problem lots are not identified
FIFO not followed Assly.- ….... 5 Mi in the sequence of 2 visually identified 7 70
Customer-Functional reciept.
failure.
End Customer -
Dissatisfaction

Next operation -
observe silvering
mark .it may rejected 1.less hopper temp
Preheating of Assly.-part get due to thermocouple
Resin/Preheating material Oprator training to
Moisture content in rejected due to poor malfunctioning &
40 8 M Process Parameter sheet 2 set parameter as 4 84
should be free from material asthetic Customer- wrong setting by optr.
per standard
part get rejected due to
moisture poor asthetic 2.Less time given
End Customer -
dissatisfaction
 PROCESS (Potential) FAILURE MODE & EFFECTS ANALYSIS Page: 01 of 01

Part Description : BLADE TRIM /BR THERMAL Process Description & Responsibility:- Anirudh Mohta FRMATE Number : SMPL/QA/FMEA/01

Part No.: FAMILY COMMON FOR ALL ECN No./Date: - Prepared By- Dharmender Yadav

Core Team: Anirudh Mohta ,Dharmender Yadav , Pramendra kr. Baiitha ,Sumeer Singh ,Tapan
Model : FANS OR ELECTRIC APPLIANCES kumar das & Damodar Sharma . Next Review Date: 10.03.2024

FMEA Date (Revision): 00

Next operation -part

Flashes/parting line High Injection
may reject/poor
flashes . Short speed/low holding time
appearance
moulding. Part & pressure Injection
Assly.-Difficulty in the First pieace
weigh less or more . speed low Barrel temp.
assy.withthe mating part approval &
50 Part Injection Moulding Excessive /less
. Customer-part get
5 Mi low Air pressure low . Process Parameter sheet 3
Inprocess inspection
4 60
deflashing of the Wrong core & punch
rejected due to poor sheeet
part along partng size less or more
appearnace
line flashes in the parision length .
End Customer -
fitment areas. Unskilled optr.
dissatisfaction

Next operation - It
create problem I n next
op. Assly.-
Visual defects such rejected
neglegency of Visual check by
60 Washing as scratch,water Customer-part get 5 Mi
respective operator
Randomy training given 3
supervisor
2 30
droplets ,soda mark rejected due to poor
appearnace
End Customer -
dissatisfaction

Next operation - create

issue in base coat
Assly.-rejected due
Dust & impression to dust & asethetically out after hooting 1
neglegency of
70 Drying of washing water poor. Customer-part 5 Mi
respective operator
parameter sheet 3 hour at time of set 2 30
droplets moisture . get rejected due to poor up
appearnace
End Customer -
dissatisfaction

Next operation - tape

test fail
Assly.-rejected due to
viscosity not proper
peel off . Customer- Viscocity not maintain visually check in
80 Base Coat or applying setting
part get rejected due
7 M
as per standard .
parameter sheet 3
cabinet
4 81
not proper
chip off End
Customer -
dissatisfaction
 PROCESS (Potential) FAILURE MODE & EFFECTS ANALYSIS Page: 01 of 01

Part Description : BLADE TRIM /BR THERMAL Process Description & Responsibility:- Anirudh Mohta FRMATE Number : SMPL/QA/FMEA/01

Part No.: FAMILY COMMON FOR ALL ECN No./Date: - Prepared By- Dharmender Yadav

Core Team: Anirudh Mohta ,Dharmender Yadav , Pramendra kr. Baiitha ,Sumeer Singh ,Tapan
Model : FANS OR ELECTRIC APPLIANCES kumar das & Damodar Sharma . Next Review Date: 10.03.2024

FMEA Date (Revision): 00

Next operation - tape

test fail
Assly.-rejected due to
peel off . Customer- Not baking as per
90 Baking base coat chip off
part get rejected due
7 M
standard time
parameter sheet 3 sctoch tape test 3 63
chip off End
Customer -
dissatisfaction

Next operation - shade

variation
Assly.-rejected due to
blackness observed redness,shade variation Alumunium foil not
100 Vaccum metalizing .kaccha .redness . Customer-part get 7 M fully loaded , time parameter sheet 3 Visually check 3 63
observed rejected shade setting
variation ,line stop
End Customer -
dissatisfaction

Next operation - shade

variation
shade not Assly.-rejected due to
matched ,dust redness,shade variation
110 top coat observe, peel off & . Customer-part get 7 M parameter sheet 3 Visually check 3 63
orange peel rejected shade
observe variation ,line stop
End Customer -
dissatisfaction

Next operation - tape

test fail
Assly.-rejected due to
out after hooting 1
peel off . Customer- Not baking as per
120 Baking base coat chip off
part get rejected due
7 M
standard time
parameter sheet 3 hour at time of set 3 63
up
chip off End
Customer -
dissatisfaction
 PROCESS (Potential) FAILURE MODE & EFFECTS ANALYSIS Page: 01 of 01

Part Description : BLADE TRIM /BR THERMAL Process Description & Responsibility:- Anirudh Mohta FRMATE Number : SMPL/QA/FMEA/01

Part No.: FAMILY COMMON FOR ALL ECN No./Date: - Prepared By- Dharmender Yadav

Core Team: Anirudh Mohta ,Dharmender Yadav , Pramendra kr. Baiitha ,Sumeer Singh ,Tapan
Model : FANS OR ELECTRIC APPLIANCES kumar das & Damodar Sharma . Next Review Date: 10.03.2024

FMEA Date (Revision): 00

Next operation - tape

test fail
Assly.-rejected due to
peel off . Customer- Not baking as per
130 Tape test Chip off
part get rejected due
7 M
standard time
parameter sheet 3 sctoch tape test 3 63
chip off End
Customer -
dissatisfaction

Next operation -part

may reject/poor
Visual defects such appearance
use proper material handling
as scratch,burn Assly.-not done . Inadequate Material
system,instruction given to 100% visual
140 Final Visual Inspection mark,air Customer-part get 4 Mi handling system,&
supervisor & training given to
2
Inspection
7 56
bubble,adhession rejected due to poor Negligence of optr.
operator & inspector .
etc. appearnace
End Customer -
dissatisfaction

Next operation -non

conformance product
may reach at customer
Security Verify the pdir enclosed Pre-dispatch
end Assly.-not QA Engineer
150 PDIR PDI not done
done . Customer-
5 Mi
negligency
with bill invoice of finised 2 inspection as per 7 70
material quality plan
complaint
End Customer -
dissatisfaction

Next operation -
Material hold
on job training to supervisor &
Packaging not as Assly.-not done .
training programme followed Counting before
per packing Customer-production 4 Mi Supervisor negligency 1 7 28
work instruction & standard dispatch
standard may hold & stop.
displayed.
End Customer
-increase waiting time.

160 Packing & identification

Next operation -difficult

to trace product.
on job training to supervisor &
Assly.-not done .
training programme followed 100% visual
Wrong Identification Customer-complaint 5 Mi Supervisor negligency 1 7 35
work instruction & standard Inspection
End
displayed.
Customer -increase
waiting time.
 PROCESS (Potential) FAILURE MODE & EFFECTS ANALYSIS Page: 01 of 01

Part Description : BLADE TRIM /BR THERMAL Process Description & Responsibility:- Anirudh Mohta FRMATE Number : SMPL/QA/FMEA/01

Part No.: FAMILY COMMON FOR ALL ECN No./Date: - Prepared By- Dharmender Yadav

Core Team: Anirudh Mohta ,Dharmender Yadav , Pramendra kr. Baiitha ,Sumeer Singh ,Tapan
Model : FANS OR ELECTRIC APPLIANCES kumar das & Damodar Sharma . Next Review Date: 10.03.2024

FMEA Date (Revision): 00

Next operation -
Difficult to process the
material
Assly.- part may get
Ink Storage not rejected due to shade
Neglegency of store instruction to be given to Cross check &
allowed in open dry variation . 5 Mi 3 4 60
inchrage supervisor & displayed WI. ensure visually .
environment Customer- part may get
rejected due to shade
variation .
End Customer -
dissatisfaction
170 Storage & Dispatch

Next operation -Qty

tracking problem
observe at customer Security Verify the
Training to supervisors display
Quantity not as per end pdir enclosed with
5 Mi Supervisor negligency work instruction & packing 2 7 70
billing invoice Assly.-…......... . bill invoice of finised
standard
Customer-complaint material
End
Customer -…..

Note: Review FMEA every 1 Year and as & when inhouse NCP's / Customer Complaints increase
Legends: Class:

Minor ( Only appearance

M1=Man M4=Method Sev : Sev : 1 & 5 Mi
discrepancy)

As per PFMEA
M2=Machine M5=M'Ment Occ: Guideline
Sev : 9 & 10 C Safety Critical Characteristic Approved By: Issued By:
Note :- Counter masure is taken if
RPN <100
Major (Fit/Function, Perform.,
M3=Matrial M6=M'Nature Detection: Sev : 6-8 M
Appear.) Characteristic
 PROCESS (Potential) FAILURE MODE & EFFECTS ANALYSIS Page: 01 of 01

Part Description : Process Description & Responsibility:- Anirudh Mohta FRMATE Number : SMPL/QA/F/02

Part No.: ECN No./Date: - Prepared By- Dharmender Yadav

Core Team: Anirudh Mohta ,Dharmender Yadav , Pramendra kr. Baiitha ,Sumeer Singh ,Tapan
Model : kumar das & Damodar Sharma . Next Review Date:

FMEA Date (Revision): 00

Action Results
s
D
e Potential Cause O

CLASS
E Responsibilit
v (s) / Mechanism (s) C Current R
Potential Failure Potential Effect (s) Current Preventive T y & Target

DETECT
PFD Stage Process Function /Requirement r of Failure C Detective P Recommended Action (s)

OCCUR
Completion Actio

R P N
Mode of Failure Controls E

SEV.
i (Consider C&E U Controls N n
C Date
t Matrix) R Taken
T
y

visuals inspection
on the bags /Ink
Raw material
container as per the
/Printing Ink not as 7 M wrong material supply …................. 1 6 42
invoice details while
per invoice
unloading the
material.
Next operation -
Difficult to process the
material
Assly.- part Get rejected
in the assly.
Customer-Fit & function
issue at custmer .
End Customer
-field failure.

visuals inspection
Raw material/Ink on the bags as per
wrong grade /shade Material Testing report /Shade
not as per 7 M 1 the invoice details 6 42
supply trial done on sampling basis
specification while unloading the
material

visuals inspection
Raw material
lot No/Batch No.not on the bags as per
without
7 M mentioned on raw ….................. 1 the invoice details 6 42
identification&
material bags while unloading the
tracebility
material

10
Incoming /verification of
raw material Next operation -
Difficult to process the
A.incoming
material mixture of coarse & inspection of the raw
Assly.- part get rejected fine granules material.
Contaminated raw due to poor asthetic
4 Mi /foreign particles …................... 3 B.Inspection during 4 48
material Customer- part get
/moisture in raw the material usage .
rejected due to poor
material C.Part inspection
asthetic .
after moulding
End Customer -
Dissatisfaction
 Incoming /verification of
PROCESS (Potential) FAILURE MODE & EFFECTS ANALYSIS Page: 01 of 01

10
raw material
Part Description : Process Description & Responsibility:- Anirudh Mohta FRMATE Number : SMPL/QA/F/02

Part No.: ECN No./Date: - Prepared By- Dharmender Yadav

Core Team: Anirudh Mohta ,Dharmender Yadav , Pramendra kr. Baiitha ,Sumeer Singh ,Tapan
Model : kumar das & Damodar Sharma . Next Review Date:

FMEA Date (Revision): 00

Next operation -
Difficult to process the
material
Assly.- part get rejected Training given
Printing Sheet due to Burning mark. Work Instruction displayed Incoming Inspection
thickness U/S Customer- part may
4 Mi IQC Neglegency Incoming standard dispalayed
2
during incoming .
4 32
get rejected due to poor
asthetic appearance .
End
Customer -…...

Next operation -
Difficult to process the
material
Assly.- part get rejected Training given
Printing Sheet due to poor adhesion Work Instruction displayed Incoming Inspection
thickness O/S Customer- part
4 Mi IQC Neglegency Incoming standard dispalayed
2
during incoming .
4 32
may get rejected due to
poor adhesion .
End Customer
-…...

Next operation -
Difficult to handle the Raw material
material Improper laoding of checked during
Damged bags/Ink Training to given to respective
Assly.- ….... 5 Mi the material /Transist 3 unloading at the 4 60
container employee
Customer-…...... damage time of reciept for
End Customer - the damage .
…...

Next operation - Mi
Difficult to find last lot of
the material .
Storage without lack of knowlwdge colour coding
Assly.- ….... 5 displayed FIFO Standard 3 4 60
FIFO /unskilled followed batchwise
Customer-…......
End Customer - Mi
…...
20 Storage of Raw Material

Next operation -
Difficult to process the
material
Assly.- part may get
Ink Storage not rejected due to shade
Neglegency of store instruction to be given to Cross check &
allowed in open dry variation . 5 Mi 3 4 60
inchrage supervisor & displayed WI. ensure visually .
environment Customer- part may get
rejected due to shade
variation .
End Customer -
dissatisfaction

identification Next operation - 100% Visual

problem to issuing 6 M 2 4 48
missing Inspection
material .
Assly.- .......
operator Negligency On job training & WI Provided
Customer- functio
failure .
100% Visual
wrong Identifictaion End Customer - 6 M 2 4 48
Disatisfaction Inspection
 PROCESS (Potential) FAILURE MODE & EFFECTS ANALYSIS Page: 01 of 01

Part Description : Process Description & Responsibility:- Anirudh Mohta FRMATE Number : SMPL/QA/F/02

Part No.: ECN No./Date: - Prepared By- Dharmender Yadav

Core Team: Anirudh Mohta ,Dharmender Yadav , Pramendra kr. Baiitha ,Sumeer Singh ,Tapan
Model : kumar das & Damodar Sharma . Next Review Date:

FMEA Date (Revision): 00

Next operation - ….......

Assly.- ….... cross -check the
Material palced at Customer-Functional material/ bin
6 M lots are not identified 2 7 84
wrong location failure. identification before
30 Transfer raw material End Customer - issuing .
Dissatisfaction

On job training & WI Provided &

Next operation - colour coding provided
improper material may
lead to functional
/manufacturing problem lots are not identified
FIFO not followed Assly.- ….... 5 Mi in the sequence of 2 visually identified 7 70
Customer-Functional reciept.
failure.
End Customer -
Dissatisfaction

Next operation -part

may reject/poor
appearance dispalyed physical master & limit
40
Screen Making as per Design not clear
Assly.-not done .
5 Mi
inadequate aweness & sample . Defect 100% visuall
design Customer-rejected due neglegency of optr. matrix dispayed inspection
to design failure training to be given
End Customer -
dissatisfaction

Next operation -part

may reject/poor
appearance
shade variation not dispalyed physical master & limit cross check with
Assly.-not done .
accepted, shade inadequate aweness & sample . Defect sample
50 Screen printing shifting b/w two
Customer-rejected due
neglegency of optr. matrix dispayed 100% visuall
to poor appearance
coats training to be given inspection
End
Customer -
dissatisfaction

Next operation -dificult

to process the material
Assly.-not
Training given
Right temp/Right done . Customer-
60 Sheet Curing time rejected due to poor
neglegency of optr. SOP displayed visually verified
Hotter sound for correct time
appearance
End Customer -
dissatisfaction
 PROCESS (Potential) FAILURE MODE & EFFECTS ANALYSIS Page: 01 of 01

Part Description : Process Description & Responsibility:- Anirudh Mohta FRMATE Number : SMPL/QA/F/02

Part No.: ECN No./Date: - Prepared By- Dharmender Yadav

Core Team: Anirudh Mohta ,Dharmender Yadav , Pramendra kr. Baiitha ,Sumeer Singh ,Tapan
Model : kumar das & Damodar Sharma . Next Review Date:

FMEA Date (Revision): 00

Next operation -dificult

to process the material
Assly.-not
Right temp/Right done . Customer- Training given
70 Forming time rejected due to poor
neglegency of optr.
SOP displayed
visually verified
appearance
End Customer -
dissatisfaction

Next operation -
observe silvering
mark .it may rejected 1.less hopper temp
Preheating of Assly.-part get due to thermocouple
Resin/Preheating material Oprator training to
Moisture content in rejected due to poor malfunctioning &
80 8 M Process Parameter sheet 2 set parameter as 4 84
should be free from material asthetic Customer- wrong setting by optr.
per standard
part get rejected due to
moisture poor asthetic 2.Less time given
End Customer -
dissatisfaction

Next operation -part

Flashes/parting line High Injection
may reject/poor
flashes . Short speed/low holding time
appearance
moulding. Part & pressure Injection
Assly.-Difficulty in the First pieace
Part Injection Moulding weigh less or more . speed low Barrel temp.
assy.withthe mating part approval &
90 Excessive /less 5 Mi low Air pressure low . Process Parameter sheet 3 4 60
cum IMD Pasting . Customer-part get Inprocess inspection
deflashing of the Wrong core & punch
rejected due to poor sheeet
part along partng size less or more
appearnace
line flashes in the parision length .
End Customer -
fitment areas. Unskilled optr.
dissatisfaction

Next operation -part

may reject/poor
Visual defects such appearance
use proper material handling
as scratch,burn Assly.-not done . Inadequate Material
system,instruction given to 100% visual
100 Final Visual Inspection mark,air Customer-part get 4 Mi handling system,&
supervisor & training given to
2
Inspection
7 56
bubble,adhession rejected due to poor Negligence of optr.
operator & inspector .
etc. appearnace
End Customer -
dissatisfaction

Next operation -
Material hold
on job training to supervisor &
Packaging not as Assly.-not done .
training programme followed Counting before
per packing Customer-production 4 Mi Supervisor negligency 1 7 28
work instruction & standard dispatch
standard may hold & stop.
displayed.
End Customer
-increase waiting time.

110 Packing & identification

 PROCESS (Potential) FAILURE MODE & EFFECTS ANALYSIS Page: 01 of 01

Part Description : Process Description & Responsibility:- Anirudh Mohta FRMATE Number : SMPL/QA/F/02

Part No.: ECN No./Date: - Prepared By- Dharmender Yadav

Core Team: Anirudh Mohta ,Dharmender Yadav , Pramendra kr. Baiitha ,Sumeer Singh ,Tapan
Model : kumar das & Damodar Sharma . Next Review Date:

FMEA Date (Revision): 00

110 Packing & identification

Next operation -difficult

to trace product.
on job training to supervisor &
Assly.-not done .
training programme followed 100% visual
Wrong Identification Customer-complaint 5 Mi Supervisor negligency 1 7 35
work instruction & standard Inspection
End
displayed.
Customer -increase
waiting time.

Next operation -non

conformance product
may reach at customer
Security Verify the pdir enclosed Pre-dispatch
end Assly.-not QA Engineer
PDI not done 5 Mi with bill invoice of finised 2 inspection as per 7 70
done . Customer- negligency
material quality plan
complaint
End Customer -
dissatisfaction

120 PDIR & Dispatch

Next operation -Qty

tracking problem
observe at customer Security Verify the
Training to supervisors display
Quantity not as per end pdir enclosed with
5 Mi Supervisor negligency work instruction & packing 2 7 70
billing invoice Assly.-…......... . bill invoice of finised
standard
Customer-complaint material
End
Customer -…..

Note: Review FMEA every 1 Year and as & when inhouse NCP's / Customer Complaints increase
Legends: Class:

Minor ( Only appearance

M1=Man M4=Method Sev : Sev : 1 & 5 Mi
discrepancy)

As per PFMEA
M2=Machine M5=M'Ment Occ: Guideline
Sev : 9 & 10 C Safety Critical Characteristic Approved By: Issued By:
Note :- Counter masure is taken if
RPN <100
Major (Fit/Function, Perform.,
M3=Matrial M6=M'Nature Detection: Sev : 6-8 M
Appear.) Characteristic
 PROCESS (Potential) FAILURE MODE & EFFECTS ANALYSIS Page: 01 of 01

Part Description : Process Description & Responsibility:- Anirudh Mohta FRMATE Number : SMPL/QA/F/02

Part No.: ECN No./Date: - Prepared By- Dharmender Yadav

Core Team: Anirudh Mohta ,Dharmender Yadav , Pramendra kr. Baitha ,Sumeer Singh ,Tapan
Model : kumar das & Damodar Sharma . Next Review Date:

FMEA Date (Revision): 00

Action Results
s
D
e Potential Cause O

CLASS
E Responsibilit
v (s) / Mechanism (s) C Current R
Potential Failure Potential Effect (s) Current Preventive T y & Target

DETECT
PFD Stage Process Function /Requirement r of Failure C Detective P Recommended Action (s)

OCCUR
Completion Actio

R P N
Mode of Failure Controls E

SEV.
i (Consider C&E U Controls N n
C Date
t Matrix) R Taken
T
y

visuals inspection
on the bags /Ink
Raw material
container as per the
/Printing Ink not as 7 M wrong material supply …................. 1 6 42
invoice details while
per invoice
unloading the
material.
Next operation -
Difficult to process the
material
Assly.- part Get rejected
in the assly.
Customer-Fit & function
issue at custmer .
End Customer
-field failure.

visuals inspection
Raw material/Ink on the bags as per
wrong grade /shade Material Testing report /Shade
not as per 7 M 1 the invoice details 6 42
supply trial done on sampling basis
specification while unloading the
material

visuals inspection
Raw material
lot No/Batch No.not on the bags as per
without
7 M mentioned on raw ….................. 1 the invoice details 6 42
identification&
material bags while unloading the
tracebility
material

10
Incoming /verification of
raw material Next operation -
Difficult to process the
A.incoming
material mixture of coarse & inspection of the raw
Assly.- part get rejected fine granules material.
Contaminated raw due to poor asthetic
4 Mi /foreign particles …................... 3 B.Inspection during 4 48
material Customer- part get
/moisture in raw the material usage .
rejected due to poor
material C.Part inspection
asthetic .
after moulding
End Customer -
Dissatisfaction
 Incoming /verification of
PROCESS (Potential) FAILURE MODE & EFFECTS ANALYSIS Page: 01 of 01

10
raw material
Part Description : Process Description & Responsibility:- Anirudh Mohta FRMATE Number : SMPL/QA/F/02

Part No.: ECN No./Date: - Prepared By- Dharmender Yadav

Core Team: Anirudh Mohta ,Dharmender Yadav , Pramendra kr. Baitha ,Sumeer Singh ,Tapan
Model : kumar das & Damodar Sharma . Next Review Date:

FMEA Date (Revision): 00

Next operation -
Difficult to process the
material
Assly.- part get rejected Training given
Printing Sheet due to Burning mark. Work Instruction displayed Incoming Inspection
thickness U/S Customer- part may
4 Mi IQC Neglegency Incoming standard dispalayed
2
during incoming .
4 32
get rejected due to poor
asthetic appearance .
End
Customer -…...

Next operation -
Difficult to process the
material
Assly.- part get rejected Training given
Printing Sheet due to poor adhesion Work Instruction displayed Incoming Inspection
thickness O/S Customer- part
4 Mi IQC Neglegency Incoming standard dispalayed
2
during incoming .
4 32
may get rejected due to
poor adhesion .
End Customer
-…...

Next operation -
Difficult to handle the Raw material
material Improper laoding of checked during
Damged bags/Ink Training to given to respective
Assly.- ….... 5 Mi the material /Transist 3 unloading at the 4 60
container employee
Customer-…...... damage time of reciept for
End Customer - the damage .
…...

Next operation - Mi
Difficult to find last lot of
the material .
Storage without lack of knowlwdge colour coding
Assly.- ….... 5 displayed FIFO Standard 3 4 60
FIFO /unskilled followed batchwise
Customer-…......
End Customer - Mi
…...
20 Storage of Raw Material

Next operation -
Difficult to process the
material
Assly.- part may get
Ink Storage not rejected due to shade
Neglegency of store instruction to be given to Cross check &
allowed in open dry variation . 5 Mi 3 4 60
inchrage supervisor & displayed WI. ensure visually .
environment Customer- part may get
rejected due to shade
variation .
End Customer -
dissatisfaction

identification Next operation - 100% Visual

problem to issuing 6 M 2 4 48
missing Inspection
material .
Assly.- .......
operator Negligency On job training & WI Provided
Customer- functio
failure .
100% Visual
wrong Identifictaion End Customer - 6 M 2 4 48
Disatisfaction Inspection
 PROCESS (Potential) FAILURE MODE & EFFECTS ANALYSIS Page: 01 of 01

Part Description : Process Description & Responsibility:- Anirudh Mohta FRMATE Number : SMPL/QA/F/02

Part No.: ECN No./Date: - Prepared By- Dharmender Yadav

Core Team: Anirudh Mohta ,Dharmender Yadav , Pramendra kr. Baitha ,Sumeer Singh ,Tapan
Model : kumar das & Damodar Sharma . Next Review Date:

FMEA Date (Revision): 00

Next operation - ….......

Assly.- ….... cross -check the
Material palced at Customer-Functional material/ bin
6 M lots are not identified 2 7 84
wrong location failure. identification before
30 Transfer raw material End Customer - issuing .
Dissatisfaction

On job training & WI Provided &

Next operation - colour coding provided
improper material may
lead to functional
/manufacturing problem lots are not identified
FIFO not followed Assly.- ….... 5 Mi in the sequence of 2 visually identified 7 70
Customer-Functional reciept.
failure.
End Customer -
Dissatisfaction

Next operation -part

may reject/poor
appearance dispalyed physical master & limit
40
Screen Making as per Design not clear
Assly.-not done .
5 Mi
inadequate aweness & sample . Defect 100% visuall
design Customer-rejected due neglegency of optr. matrix dispayed inspection
to design failure training to be given
End Customer -
dissatisfaction

Next operation -part

may reject/poor
appearance
shade variation not dispalyed physical master & limit cross check with
Assly.-not done .
accepted, shade inadequate aweness & sample . Defect sample
50 Screen printing shifting b/w two
Customer-rejected due
neglegency of optr. matrix dispayed 100% visuall
to poor appearance
coats training to be given inspection
End
Customer -
dissatisfaction

Next operation -dificult

to process the material
Assly.-not
Training given
Right temp/Right done . Customer-
60 Sheet Curing time rejected due to poor
neglegency of optr. SOP displayed visually verified
Hotter sound for correct time
appearance
End Customer -
dissatisfaction
 PROCESS (Potential) FAILURE MODE & EFFECTS ANALYSIS Page: 01 of 01

Part Description : Process Description & Responsibility:- Anirudh Mohta FRMATE Number : SMPL/QA/F/02

Part No.: ECN No./Date: - Prepared By- Dharmender Yadav

Core Team: Anirudh Mohta ,Dharmender Yadav , Pramendra kr. Baitha ,Sumeer Singh ,Tapan
Model : kumar das & Damodar Sharma . Next Review Date:

FMEA Date (Revision): 00

Next operation -dificult

to process the material
Assly.-not
Right temp/Right done . Customer- Training given
70 Forming time rejected due to poor
M neglegency of optr.
SOP displayed
visually verified
appearance
End Customer -
dissatisfaction

Next operation - Part

get rejected
1.less hopper temp
Assly.-part get rejected
due to thermocouple
due to poor asthetic
NO U/S. malfunctioning &
80 Cutting NO O/S
Customer-part get 8 M
wrong setting by optr.
Process Parameter sheet 2 4 84
rejected due to poor
asthetic
2.Less time given
End Customer -
dissatisfaction

Next operation -part

Flashes/parting line High Injection
may reject/poor
flashes . Short speed/low holding time
appearance
moulding. Part & pressure Injection
Assly.-Difficulty in the First pieace
weigh less or more . speed low Barrel temp.
assy.withthe mating part approval &
90 Part Injection Moulding Excessive /less
. Customer-part get
5 Mi low Air pressure low . Process Parameter sheet 3
Inprocess inspection
4 60
deflashing of the Wrong core & punch
rejected due to poor sheeet
part along partng size less or more
appearnace
line flashes in the parision length .
End Customer -
fitment areas. Unskilled optr.
dissatisfaction

Next operation -part

may reject/poor
Visual defects such appearance
use proper material handling
as scratch,burn Assly.-not done . Inadequate Material
system,instruction given to 100% visual
100 Final Visual Inspection mark,air Customer-part get 4 Mi handling system,&
supervisor & training given to
2
Inspection
7 56
bubble,adhession rejected due to poor Negligence of optr.
operator & inspector .
etc. appearnace
End Customer -
dissatisfaction

Next operation -
Material hold
on job training to supervisor &
Packaging not as Assly.-not done .
training programme followed Counting before
per packing Customer-production 4 Mi Supervisor negligency 1 7 28
work instruction & standard dispatch
standard may hold & stop.
displayed.
End Customer
-increase waiting time.

110 Packing & identification

 PROCESS (Potential) FAILURE MODE & EFFECTS ANALYSIS Page: 01 of 01

Part Description : Process Description & Responsibility:- Anirudh Mohta FRMATE Number : SMPL/QA/F/02

Part No.: ECN No./Date: - Prepared By- Dharmender Yadav

Core Team: Anirudh Mohta ,Dharmender Yadav , Pramendra kr. Baitha ,Sumeer Singh ,Tapan
Model : kumar das & Damodar Sharma . Next Review Date:

FMEA Date (Revision): 00

110 Packing & identification

Next operation -difficult

to trace product.
on job training to supervisor &
Assly.-not done .
training programme followed 100% visual
Wrong Identification Customer-complaint 5 Mi Supervisor negligency 1 7 35
work instruction & standard Inspection
End
displayed.
Customer -increase
waiting time.

Next operation -non

conformance product
may reach at customer
Security Verify the pdir enclosed Pre-dispatch
end Assly.-not QA Engineer
PDI not done 5 Mi with bill invoice of finised 2 inspection as per 7 70
done . Customer- negligency
material quality plan
complaint
End Customer -
dissatisfaction

120 PDIR & Dispatch

Next operation -Qty

tracking problem
observe at customer Security Verify the
Training to supervisors display
Quantity not as per end pdir enclosed with
5 Mi Supervisor negligency work instruction & packing 2 7 70
billing invoice Assly.-…......... . bill invoice of finised
standard
Customer-complaint material
End
Customer -…..

Note: Review FMEA every 1 Year and as & when inhouse NCP's / Customer Complaints increase
Legends: Class:

Minor ( Only appearance

M1=Man M4=Method Sev : Sev : 1 & 5 Mi
discrepancy)

As per PFMEA
M2=Machine M5=M'Ment Occ: Guideline
Sev : 9 & 10 C Safety Critical Characteristic Approved By: Issued By:
Note :- Counter masure is taken if
RPN <100
Major (Fit/Function, Perform.,
M3=Matrial M6=M'Nature Detection: Sev : 6-8 M
Appear.) Characteristic
 PROCESS (Potential) FAILURE MODE & EFFECTS ANALYSIS Page: 01 of 01

Part Description : BLADE TRIM /UV Process Description & Responsibility:- Anirudh Mohta FRMATE Number : SMPL/QA/FMEA/01

Part No.: FAMILY COMMON FOR ALL ECN No./Date: - Prepared By- Dharmender Yadav

Core Team: Anirudh Mohta ,Dharmender Yadav , Pramendra kr. Baiitha ,Sumeer Singh ,Tapan
Model : FANS OR ELECTRIC APPLIANCES kumar das & Damodar Sharma . Next Review Date: 10.03.2024

FMEA Date (Revision): 00

s Action Results
D
e Potential Cause O

CLASS
E Responsibilit
v (s) / Mechanism (s) C Current R
Potential Failure Potential Effect (s) Current Preventive T y & Target

DETECT
PFD Stage Process Function /Requirement r of Failure C Detective P Recommended Action (s)

OCCUR
Completion Actio

R P N
Mode of Failure Controls E

SEV.
i (Consider C&E U Controls N n
C Date
t Matrix) R Taken
T
y

visuals inspection
on the bags /Ink
Raw material
container as per the
/Printing Ink not as 7 M wrong material supply …................. 1 6 42
invoice details while
per invoice
unloading the
Next operation - material.
Difficult to process the
material
Assly.- part Get rejected
in the assly.
Customer-Fit & function
issue at custmer .
End Customer
-field failure.

10
Incoming /verification of visuals inspection
raw material Raw material/Ink on the bags as per
wrong grade /shade Material Testing report /Shade
not as per 7 M 1 the invoice details 6 42
supply trial done on sampling basis
specification while unloading the
material

visuals inspection
Raw material
lot No/Batch No.not on the bags as per
without
7 M mentioned on raw ….................. 1 the invoice details 6 42
identification&
material bags while unloading the
tracebility
material

Next operation -
Difficult to process the
A.incoming
material mixture of coarse & inspection of the raw
Assly.- part get rejected fine granules material.
Contaminated raw due to poor asthetic
4 Mi /foreign particles …................... 3 B.Inspection during 4 48
material Customer- part get
/moisture in raw the material usage .
rejected due to poor
material C.Part inspection
asthetic .
after moulding
End Customer -
Dissatisfaction

Next operation -
Difficult to handle the Raw material
material Improper laoding of checked during
Damged bags/Ink Training to given to respective
Assly.- ….... 5 Mi the material /Transist 3 unloading at the 4 60
container employee
Customer-…...... damage time of reciept for
End Customer - the damage .
…...

Next operation - Mi
Difficult to find last lot of
the material .
Storage without lack of knowlwdge colour coding
Assly.- ….... 5 displayed FIFO Standard 3 4 60
FIFO /unskilled followed batchwise
Customer-…......
End Customer -
…...
20 Storage of Raw Material
 PROCESS (Potential) FAILURE MODE & EFFECTS ANALYSIS Page: 01 of 01

Part Description : BLADE TRIM /UV Process Description & Responsibility:- Anirudh Mohta FRMATE Number : SMPL/QA/FMEA/01

Part No.: FAMILY COMMON FOR ALL ECN No./Date: - Prepared By- Dharmender Yadav

Core Team: Anirudh Mohta ,Dharmender Yadav , Pramendra kr. Baiitha ,Sumeer Singh ,Tapan
Model : FANS OR ELECTRIC APPLIANCES Next operation - kumar das & Damodar Sharma . Next Review Date: 10.03.2024
Difficult to find last lot of
the material . FMEA Date (Revision): 00
Storage without lack of knowlwdge colour coding
Assly.- ….... 5 displayed FIFO Standard 3 4 60
FIFO /unskilled followed batchwise
Customer-…......
End Customer -
…... Mi
20 Storage of Raw Material

Next operation -
Difficult to process the
material
Assly.- part may get
Ink Storage not rejected due to shade
Neglegency of store instruction to be given to Cross check &
allowed in open dry variation . 5 Mi 3 4 60
inchrage supervisor & displayed WI. ensure visually .
environment Customer- part may get
rejected due to shade
variation .
End Customer -
dissatisfaction

identification Next operation - 100% Visual

problem to issuing 6 M 2 4 48
missing Inspection
material .
Assly.- .......
operator Negligency On job training & WI Provided
Customer- functio
failure .
100% Visual
wrong Identifictaion End Customer - 6 M 2 4 48
Disatisfaction Inspection

Next operation - ….......

Assly.- ….... cross -check the
Material palced at Customer-Functional material/ bin
6 M lots are not identified 2 7 84
wrong location failure. identification before
30 Transfer raw material End Customer - issuing .
Dissatisfaction

On job training & WI Provided &

Next operation - colour coding provided
improper material may
lead to functional
/manufacturing problem lots are not identified
FIFO not followed Assly.- ….... 5 Mi in the sequence of 2 visually identified 7 70
Customer-Functional reciept.
failure.
End Customer -
Dissatisfaction

Next operation -
observe silvering
mark .it may rejected 1.less hopper temp
Preheating of Assly.-part get due to thermocouple
Resin/Preheating material Oprator training to
Moisture content in rejected due to poor malfunctioning &
40 8 M Process Parameter sheet 2 set parameter as 4 84
should be free from material asthetic Customer- wrong setting by optr.
per standard
part get rejected due to
moisture poor asthetic 2.Less time given
End Customer -
dissatisfaction
 PROCESS (Potential) FAILURE MODE & EFFECTS ANALYSIS Page: 01 of 01

Part Description : BLADE TRIM /UV Process Description & Responsibility:- Anirudh Mohta FRMATE Number : SMPL/QA/FMEA/01

Part No.: FAMILY COMMON FOR ALL ECN No./Date: - Prepared By- Dharmender Yadav

Core Team: Anirudh Mohta ,Dharmender Yadav , Pramendra kr. Baiitha ,Sumeer Singh ,Tapan
Model : FANS OR ELECTRIC APPLIANCES kumar das & Damodar Sharma . Next Review Date: 10.03.2024

FMEA Date (Revision): 00

Next operation -part

Flashes/parting line High Injection
may reject/poor
flashes . Short speed/low holding time
appearance
moulding. Part & pressure Injection
Assly.-Difficulty in the First pieace
weigh less or more . speed low Barrel temp.
assy.withthe mating part approval &
50 Part Injection Moulding Excessive /less
. Customer-part get
5 Mi low Air pressure low . Process Parameter sheet 3
Inprocess inspection
4 60
deflashing of the Wrong core & punch
rejected due to poor sheeet
part along partng size less or more
appearnace
line flashes in the parision length .
End Customer -
fitment areas. Unskilled optr.
dissatisfaction

Next operation - It
create problem I n next
op. Assly.-
Visual defects such rejected
neglegency of Visual check by
60 Washing as scratch,water Customer-part get 5 Mi
respective operator
Randomy training given 3
supervisor
2 30
droplets ,soda mark rejected due to poor
appearnace
End Customer -
dissatisfaction

Next operation - create

issue in base coat
Assly.-rejected due
Dust & impression to dust & asethetically out after hooting 1
neglegency of
70 Drying of washing water poor. Customer-part 5 Mi
respective operator
parameter sheet 3 hour at time of set 2 30
droplets moisture . get rejected due to poor up
appearnace
End Customer -
dissatisfaction

Next operation - tape

test fail
Assly.-rejected due to
viscosity not proper
peel off . Customer- Viscocity not maintain visually check in
80 UV Base Coat or applying setting
part get rejected due
7 M
as per standard .
parameter sheet 3
cabinet
4 81
not proper
chip off End
Customer -
dissatisfaction
 PROCESS (Potential) FAILURE MODE & EFFECTS ANALYSIS Page: 01 of 01

Part Description : BLADE TRIM /UV Process Description & Responsibility:- Anirudh Mohta FRMATE Number : SMPL/QA/FMEA/01

Part No.: FAMILY COMMON FOR ALL ECN No./Date: - Prepared By- Dharmender Yadav

Core Team: Anirudh Mohta ,Dharmender Yadav , Pramendra kr. Baiitha ,Sumeer Singh ,Tapan
Model : FANS OR ELECTRIC APPLIANCES kumar das & Damodar Sharma . Next Review Date: 10.03.2024

FMEA Date (Revision): 00

Next operation - shade

variation
Assly.-rejected due to
blackness observed redness,shade variation Alumunium foil not
90 Vaccum metalizing .kaccha .redness . Customer-part get 7 M fully loaded , time parameter sheet 3 Visually check 3 63
observed rejected shade setting
variation ,line stop
End Customer -
dissatisfaction

Next operation - shade

variation
shade not Assly.-rejected due to
matched ,dust redness,shade variation
100 top coat observe, peel off & . Customer-part get 7 M parameter sheet 3 Visually check 3 63
orange peel rejected shade
observe variation ,line stop
End Customer -
dissatisfaction

Next operation - tape

test fail
Assly.-rejected due to
peel off . Customer- Not baking as per
110 Tape test Chip off
part get rejected due
7 M
standard time
parameter sheet 3 sctoch tape test 3 63
chip off End
Customer -
dissatisfaction

Next operation -part

may reject/poor
Visual defects such appearance
use proper material handling
as scratch,burn Assly.-not done . Inadequate Material
system,instruction given to 100% visual
120 Final Visual Inspection mark,air Customer-part get 4 Mi handling system,&
supervisor & training given to
2
Inspection
7 56
bubble,adhession rejected due to poor Negligence of optr.
operator & inspector .
etc. appearnace
End Customer -
dissatisfaction
 PROCESS (Potential) FAILURE MODE & EFFECTS ANALYSIS Page: 01 of 01

Part Description : BLADE TRIM /UV Process Description & Responsibility:- Anirudh Mohta FRMATE Number : SMPL/QA/FMEA/01

Part No.: FAMILY COMMON FOR ALL ECN No./Date: - Prepared By- Dharmender Yadav

Core Team: Anirudh Mohta ,Dharmender Yadav , Pramendra kr. Baiitha ,Sumeer Singh ,Tapan
Model : FANS OR ELECTRIC APPLIANCES kumar das & Damodar Sharma . Next Review Date: 10.03.2024

FMEA Date (Revision): 00

Next operation -non

conformance product
may reach at customer
Security Verify the pdir enclosed Pre-dispatch
end Assly.-not QA Engineer
130 PDIR PDI not done
done . Customer-
5 Mi
negligency
with bill invoice of finised 2 inspection as per 7 70
material quality plan
complaint
End Customer -
dissatisfaction

Next operation -
Material hold
on job training to supervisor &
Packaging not as Assly.-not done .
training programme followed Counting before
per packing Customer-production 4 Mi Supervisor negligency 1 7 28
work instruction & standard dispatch
standard may hold & stop.
displayed.
End Customer
-increase waiting time.

140 Packing & identification

Next operation -difficult

to trace product.
on job training to supervisor &
Assly.-not done .
training programme followed 100% visual
Wrong Identification Customer-complaint 5 Mi Supervisor negligency 1 7 35
work instruction & standard Inspection
End
displayed.
Customer -increase
waiting time.

Next operation -
Difficult to process the
material
Assly.- part may get
Ink Storage not rejected due to shade
Neglegency of store instruction to be given to Cross check &
allowed in open dry variation . 5 Mi 3 4 60
inchrage supervisor & displayed WI. ensure visually .
environment Customer- part may get
rejected due to shade
variation .
End Customer -
dissatisfaction
150 Storage & Dispatch

Next operation -Qty

tracking problem
observe at customer Security Verify the
Training to supervisors display
Quantity not as per end pdir enclosed with
5 Mi Supervisor negligency work instruction & packing 2 7 70
billing invoice Assly.-…......... . bill invoice of finised
standard
Customer-complaint material
End
Customer -…..

Note: Review FMEA every 1 Year and as & when inhouse NCP's / Customer Complaints increase
Legends: Class:

Minor ( Only appearance

M1=Man M4=Method Sev : Sev : 1 & 5 Mi
discrepancy)

As per PFMEA
Guideline
 PROCESS (Potential) FAILURE MODE & EFFECTS ANALYSIS Page: 01 of 01

Part Description : BLADE TRIM /UV Process Description & Responsibility:- Anirudh Mohta FRMATE Number : SMPL/QA/FMEA/01

Part No.: FAMILY COMMON FOR ALL ECN No./Date: - Prepared By- Dharmender Yadav

Core Team: Anirudh Mohta ,Dharmender Yadav , Pramendra kr. Baiitha ,Sumeer Singh ,Tapan
Model : FANS OR ELECTRIC APPLIANCES kumar das & Damodar Sharma . Next Review Date: 10.03.2024

FMEA Date (Revision): 00

As per PFMEA
M2=Machine M5=M'Ment Occ: Guideline
Sev : 9 & 10 C Safety Critical Characteristic Approved By: Issued By:
Note :- Counter masure is taken if
RPN <100
Major (Fit/Function, Perform.,
M3=Matrial M6=M'Nature Detection: Sev : 6-8 M
Appear.) Characteristic
 PROCESS (Potential) FAILURE MODE & EFFECTS ANALYSIS Page: 01 of 01

Part Description : DIFFUSER ASSEMBLY AERIS Process Description & Responsibility:- Anirudh Mohta FRMATE Number : SMPL/QA/FMEA/01

Part No.: 23D-04S ECN No./Date: - Prepared By- Dharmender Yadav

Core Team: Anirudh Mohta ,Dharmender Yadav , Pramendra kr. Baiitha ,Sumeer Singh ,Tapan kumar
Model : CELING FANS das & Damodar Sharma . Next Review Date: 24.02.2024

FMEA Date (Revision): 00

Action Results
s
D
e Potential Cause O

CLASS
E Responsibilit
v (s) / Mechanism (s) C Current R
Potential Failure Potential Effect (s) Current Preventive T y & Target

DETECT
PFD Stage Process Function /Requirement r of Failure C Detective P Recommended Action (s)

OCCUR
Completion Actio

R P N
Mode of Failure Controls E

SEV.
i (Consider C&E U Controls N n
C Date
t Matrix) R Taken
T
y

visuals inspection
on the bags /Ink
Raw material
container as per the
/Printing Ink not as 7 M wrong material supply …................. 1 6 42
invoice details while
per invoice
unloading the
Next operation - material.
Difficult to process the
material
Assly.- part Get rejected
in the assly.
Customer-Fit & function
issue at custmer .
End Customer
-field failure.

10
Incoming /verification of visuals inspection
raw material Raw material/Ink on the bags as per
wrong grade /shade Material Testing report /Shade
not as per 7 M 1 the invoice details 6 42
supply trial done on sampling basis
specification while unloading the
material

visuals inspection
Raw material
lot No/Batch No.not on the bags as per
without
7 M mentioned on raw ….................. 1 the invoice details 6 42
identification&
material bags while unloading the
tracebility
material

Next operation -
Difficult to process the
A.incoming
material mixture of coarse & inspection of the raw
Assly.- part get rejected fine granules material.
Contaminated raw due to poor asthetic
4 Mi /foreign particles …................... 3 B.Inspection during 4 48
material Customer- part get
/moisture in raw the material usage .
rejected due to poor
material C.Part inspection
asthetic .
after moulding
End Customer -
Dissatisfaction

Next operation -
Difficult to handle the Raw material
material Improper laoding of checked during
Damged bags/Ink Training to given to respective
Assly.- ….... 5 Mi the material /Transist 3 unloading at the 4 60
container employee
Customer-…...... damage time of reciept for
End Customer - the damage .
…...

Next operation - Mi
Difficult to find last lot of
the material .
Storage without lack of knowlwdge colour coding
Assly.- ….... 5 displayed FIFO Standard 3 4 60
FIFO /unskilled followed batchwise
Customer-…......
End Customer -
…...
 PROCESS (Potential) FAILURE MODE & EFFECTS ANALYSIS Page: 01 of 01

Part Description : DIFFUSER ASSEMBLY AERIS Process Description & Responsibility:- Anirudh Mohta FRMATE Number : SMPL/QA/FMEA/01

Part No.: 23D-04S ECN No./Date: - Prepared By- Dharmender Yadav

Core Team: Anirudh Mohta ,Dharmender Yadav , Pramendra kr. Baiitha ,Sumeer Singh ,Tapan kumar
Model : CELING FANS Next operation - das & Damodar Sharma . Next Review Date: 24.02.2024
Difficult to find last lot of
the material . FMEA Date (Revision): 00
Storage without lack of knowlwdge colour coding
Assly.- ….... 5 displayed FIFO Standard 3 4 60
FIFO /unskilled followed batchwise
Customer-…......
End Customer -
…... Mi
20 Storage of Raw Material

Next operation -
Difficult to process the
material
Assly.- part may get
Ink Storage not rejected due to shade
Neglegency of store instruction to be given to Cross check &
allowed in open dry variation . 5 Mi 3 4 60
inchrage supervisor & displayed WI. ensure visually .
environment Customer- part may get
rejected due to shade
variation .
End Customer -
dissatisfaction

identification Next operation - 100% Visual

problem to issuing 6 M 2 4 48
missing Inspection
material .
Assly.- .......
operator Negligency On job training & WI Provided
Customer- functio
failure .
100% Visual
wrong Identifictaion End Customer - 6 M 2 4 48
Disatisfaction Inspection

Next operation - ….......

Assly.- ….... cross -check the
Material palced at Customer-Functional material/ bin
6 M lots are not identified 2 7 84
wrong location failure. identification before
30 Transfer raw material End Customer - issuing .
Dissatisfaction

On job training & WI Provided &

Next operation - colour coding provided
improper material may
lead to functional
/manufacturing problem lots are not identified
FIFO not followed Assly.- ….... 5 Mi in the sequence of 2 visually identified 7 70
Customer-Functional reciept.
failure.
End Customer -
Dissatisfaction

Next operation -
observe silvering
mark .it may rejected 1.less hopper temp
Preheating of Assly.-part get due to thermocouple
Resin/Preheating material Oprator training to
Moisture content in rejected due to poor malfunctioning &
40 8 M Process Parameter sheet 2 set parameter as 4 84
should be free from material asthetic Customer- wrong setting by optr.
per standard
part get rejected due to
moisture poor asthetic 2.Less time given
End Customer -
dissatisfaction
 PROCESS (Potential) FAILURE MODE & EFFECTS ANALYSIS Page: 01 of 01

Part Description : DIFFUSER ASSEMBLY AERIS Process Description & Responsibility:- Anirudh Mohta FRMATE Number : SMPL/QA/FMEA/01

Part No.: 23D-04S ECN No./Date: - Prepared By- Dharmender Yadav

Core Team: Anirudh Mohta ,Dharmender Yadav , Pramendra kr. Baiitha ,Sumeer Singh ,Tapan kumar
Model : CELING FANS das & Damodar Sharma . Next Review Date: 24.02.2024

FMEA Date (Revision): 00

Next operation -part

Flashes/parting line High Injection
may reject/poor
flashes . Short speed/low holding time
appearance
moulding. Part & pressure Injection
Assly.-Difficulty in the First pieace
weigh less or more . speed low Barrel temp.
assy.withthe mating part approval &
50 Part Injection Moulding Excessive /less
. Customer-part get
5 Mi low Air pressure low . Process Parameter sheet 3
Inprocess inspection
4 60
deflashing of the Wrong core & punch
rejected due to poor sheeet
part along partng size less or more
appearnace
line flashes in the parision length .
End Customer -
fitment areas. Unskilled optr.
dissatisfaction

Next operation - It
create problem I n next
op. Assly.-
Visual defects such rejected
neglegency of Visual check by
60 Assembly/PU Paints as scratch,water Customer-part get 5 Mi
respective operator
Randomy training given 3
supervisor
2 30
droplets ,soda mark rejected due to poor
appearnace
End Customer -
dissatisfaction

Next operation -part

may reject/poor
Visual defects such appearance
use proper material handling
as scratch,burn Assly.-not done . Inadequate Material
system,instruction given to 100% visual
70 Final Visual Inspection mark,air Customer-part get 4 Mi handling system,&
supervisor & training given to
2
Inspection
7 56
bubble,adhession rejected due to poor Negligence of optr.
operator & inspector .
etc. appearnace
End Customer -
dissatisfaction

Next operation -non

conformance product
may reach at customer
Security Verify the pdir enclosed Pre-dispatch
end Assly.-not QA Engineer
80 PDIR PDI not done
done . Customer-
5 Mi
negligency
with bill invoice of finised 2 inspection as per 7 70
material quality plan
complaint
End Customer -
dissatisfaction

Next operation -
Material hold
on job training to supervisor &
Packaging not as Assly.-not done .
training programme followed Counting before
per packing Customer-production 4 Mi Supervisor negligency 1 7 28
work instruction & standard dispatch
standard may hold & stop.
displayed.
End Customer
-increase waiting time.

90 Packing & identification

 PROCESS (Potential) FAILURE MODE & EFFECTS ANALYSIS Page: 01 of 01

Part Description : DIFFUSER ASSEMBLY AERIS Process Description & Responsibility:- Anirudh Mohta FRMATE Number : SMPL/QA/FMEA/01

Part No.: 23D-04S ECN No./Date: - Prepared By- Dharmender Yadav

Core Team: Anirudh Mohta ,Dharmender Yadav , Pramendra kr. Baiitha ,Sumeer Singh ,Tapan kumar
Model : CELING FANS das & Damodar Sharma . Next Review Date: 24.02.2024

FMEA Date (Revision): 00

90 Packing & identification

Next operation -difficult

to trace product.
on job training to supervisor &
Assly.-not done .
training programme followed 100% visual
Wrong Identification Customer-complaint 5 Mi Supervisor negligency 1 7 35
work instruction & standard Inspection
End
displayed.
Customer -increase
waiting time.

Next operation -
Difficult to process the
material
Assly.- part may get
Ink Storage not rejected due to shade
Neglegency of store instruction to be given to Cross check &
allowed in open dry variation . 5 Mi 3 4 60
inchrage supervisor & displayed WI. ensure visually .
environment Customer- part may get
rejected due to shade
variation .
End Customer -
dissatisfaction
100 Storage & Dispatch

Next operation -Qty

tracking problem
observe at customer Security Verify the
Training to supervisors display
Quantity not as per end pdir enclosed with
5 Mi Supervisor negligency work instruction & packing 2 7 70
billing invoice Assly.-…......... . bill invoice of finised
standard
Customer-complaint material
End
Customer -…..

Note: Review FMEA every 1 Year and as & when inhouse NCP's / Customer Complaints increase
Legends: Class:

Minor ( Only appearance

M1=Man M4=Method Sev : Sev : 1 & 5 Mi
discrepancy)

As per PFMEA
M2=Machine M5=M'Ment Occ: Guideline
Sev : 9 & 10 C Safety Critical Characteristic Approved By: Issued By:
Note :- Counter masure is taken if
RPN <100
Major (Fit/Function, Perform.,
M3=Matrial M6=M'Nature Detection: Sev : 6-8 M
Appear.) Characteristic