Process Flow Diagram

Part Number /4500305696 SYMBOLS

Part Name / Description: FRP moulded gratting 25 mm height, Mesh Size 38X38mm. (Colo-gray) TRANSPORTATION OPERATION STORAGE DELAY

Supplier / Plant: EPP Unit No-5C Vendor Code: OPN & INSP. TOGETHER INCOMING PARTS INSPECTION

Supplier's Approving Authority / Date: Mr. Nirav Saha

Origin Date/No.: :26-05-2024 PFD NO. :- 01 REV. DATE :- 5/26/2024 REV. NO. :- 00

Requirements
Op. No. Process Description Incoming source of variation Process Flow diagram
Characteristic ID Product Characteristics Process Characteristics Class

Material : Resin
No different grade than Resin
Grade :-Isophthalic polyester (FR Grade 1 As per the CP
Grade :-Isophthalic polyester (FR Grade V1,UV)
V1,UV) different grade

Wrong invoice 2 No gate entry with wrong invoice As per invoice

Receipt of material
Dust, dirt and contamination on material 3 No dust,dirt and contamination As per daily 5s
1.Material :- Fiber glass
10 Grade:- 2400TEX
2.Material : Resin
Lot/Batch traceability missing 4 No lot/batch traceability missing Barcode verification

Grade :-Isophthalic polyester (FR Grade V1,UV)

Over stacking of material bags/bins 5 No over stacking Max 6 feet stacking height

Material received in damaged packaging

6 Material in standard packaging As per standard packaging
(bags, bin etc.)
Packaging condition as per standard and lot quantity as
Lot quantity and weight 7 As per standard packaging and invoice
per invoice

Fork lift not available 8 Fork lift available PM of fork lift

Without IQC confirmation/uninspected

1 No material moving without IQC conformation As per procedure
material move their final storage location

Low/high density @27 ℃ 2 1.09 to1.11 Cross varification of supplie TC.

Less/more GELtime 3 12 to 15 mint. As per test certificate verification

Incoming inspection & testing of material then

20 send to stor.
Less Peak Exotherm 4 More than 150 ℃. Cross varification of supplie TC.

No different grade than Resin

Test certificate verification 5 As per the CP
Grade :-Isophthalic polyester (FR Grade V1,UV)

Acid Value Out Spec. 6 14 to 18 mg KOH/g Cross varification of supplie TC.

Less/more Viscocity @25 ℃ 7 500-600 cps Cross varification of supplie TC.

Material not stored in defined location 1 Material storage in defined location As per the Dedicated racks defined for RM.

Material pick list not as per Work order 2 Material pick list asper work order As per material pick list

GRIN & LRN rejection mixed with ok

3 No material mix-up As per GRIN rejectionprocedure
material

Material is stroed wrong condition 4 Material stroed in good condition As per WI

30 Material handling in store area
Wrong format for label 5 Correct format of label As per the label matrix

Spilage of material 6 No spillage of raw material As per the Handling WI

Self life not monitoring 7 No out of self life material Cross varification of self life for each material

FIFO not followed 9 Follow FIFO As per FIFO

Material loaded in wrong bin/dryer

1 No wrong material loading As per the material loadinge report
Wrong materail loaded.

Wrong material issued 2 Correct material as per requirment Verification against the requeision sheet

40 Material sed to shop floor Less/more Qty. issued 3 No less/more QTY. against list As per the requestion list

Mix of batch/lot 4 No mix batch allowed for same batch production One batch for production

Material mix-up 5 No material mix-up As per work instruction

Temp. Not maintned 1 Temp. need to be maintained as per the requirment As per the Set up check sheet

Wrong ejector pin position 2 Correct ejector pin position As per the Set up check sheet

50 Mold set up Wrong orientation of metal blocks 3 Correct orientation of metal blocks As per the Set up check sheet

Incorrect log size for customization 4 Correct log size for gratting As per the Set up check sheet
50 Mold set up

Mold clean and neatness not followed 5 Clean and neat mold for grtting process As per the Set up check sheet

Mould reediness not done for gratting

1 Mold ready for Gratting fill-up
fillup (Wax/releser application)

Mold damage 2 No mold damage

60 Mold preparation(Wax/releaser application)

Bad surface finish 3 No bad surface finish allowed
As per Wax/releser aplicationWI

Jam during release 4 No jam during release allowed

Visual damage 5 No visual damage allowed

Formulation not followed 1 Correct formulation As per the formulation sheet

less /more mixing time 2 Correct mixxing time

Wrong mixing ratio 3 Correct mixing ration

Forigen particels in the mixed resin 4 No forigen particles allowed in the slurry As per WI
70 Slurry prepartion

Less/more viscocity of slurry 5 Correct viscocity of slurry

Fire ritardant not used as per the

6 Use of FR as per the requirment
requirment

Slurry Shade not matching with the

7 Slurry shade match with master shade
master shade

More/less slurry preparation 8 No more/less slurry preparation As per the requestion sheet

roving lay-up not done as per height

1 roving lay-up as per the height requirment Asper the gratting WI
requirmnet

Incorrect no of roving in pipe 2 Correct no of roving in the pipe.

No .of pressing not followed 3 Pressing as per the requiment of height Asper the gratting WI

80 Gratting Fill-up process

Wrong roving orientation 4 Correct roving orientation

Wrong ratio of Glass and resin 5 Correct ratio of glass and resin

Resin puring not done as per requirment 6 Resin puring asper the requirment Asper the gratting WI
 Hot water not released to the mold 1 Hot water released to the mold Asper the gratting WI

Hot water temp not correct 2 Correct temp. of hot water

90 Curring process(Cooling/heating)
Hot water running time less 3 Correct time of hot water running

Cool water not releassed to the mold 4 Cool water relesed to the mold Asper the gratting WI

Proper demolding not done 1 Proper demolding (Without damage) Asper the gratting WI

100 De molding
Ejector pin mark on the part 2 No ejector pin mark on the part

Flash on the part 3

FPA not followed 1 Without FPA production can not start Asper the FPA report

1. Procedure not followed

2 FPA procedure to be followed Asper the inspection procedure
2. CP inspection frequency not followed
110 FPA inspection
Uncelebrated instruments not taken
3 Calibrated instruments to beused As per the calibration list
back from shop floor

Part not checked as per the QAP. 4 Part to be checked against the QAP requirment As per approved QAP

Inprocess inspectionskiped 1 Inprocess inspectionas per plan Asper the procedure

120 Inprocess inspection Part dimensions not as per drawing 2 Part dimension asper drawing Asper the drawing/CP

Part color mismatch 3 Part colorLight gray(RAL-7035) As per the limit sample

Final part dimension as perdrawing 1 Part dimension asper drawing Asper the drawing/CP

Finalpart finishing not ok 2 Finishing asper part drawing Asper the drawing/CP
130 Final inspection
Part color mismatch 3 Part colorLight gray(RAL-7035) As per the limit sample

Part testing as per QAP 4 Ok testing as per the QAP Asper the drawing/CP

140 Packaging Packaging not as per the strnderd. 1 Packaging as per the sternderd Asper the packaging strnderd.

Sr. No. Rev No Rev. Date Issue Date Reason for changed Prepared By Checked BY Approved By
1 00
2 01
3 02
4 03
Product Name

FRP moulded gratting 25 mm height, Mesh Size 38X38mm. (Colo-gray)

Product Code

4500305696

Core team:

Operation
Op. No. Characteristics
description

No different grade than Resin

Grade :-Isophthalic polyester (FR Grade V1,UV)

No gate entry with wrong invoice

No dust,dirt and contamination

Receipt of material

1.Material :- Fiber
No lot/batch traceability missing
glass
Grade:- 2400TEX
10
2.Material : Resin
Grade :-Isophthalic
polyester (FR Grade
V1,UV)
 Receipt of material

1.Material :- Fiber
glass
Grade:- 2400TEX
10
2.Material : Resin
Grade :-Isophthalic
No over stacking
polyester (FR Grade
V1,UV)

Material in standard packaging

Packaging condition as per standard and lot

quantity as per invoice

Fork lift available

No material moving without IQC conformation

1.09 to1.11

Incoming inspection 12 to 15 mint.

20 & testing of material
then send to stor. More than 150 ℃.

No different grade than Resin

Grade :-Isophthalic polyester (FR Grade V1,UV)

14 to 18 mg KOH/g

500-600 cps

Material storage in defined location

Material handling in
30
 Material pick list asper work order

No material mix-up
Material handling in
30
store area
Material stroed in good condition

Correct format of label

No spillage of raw material

No out of self life material

Follow FIFO

No wrong material loading

Correct material as per requirment

Material sed to shop

40 No less/more QTY. against list
floor
 Material sed to shop
40
floor

No mix batch allowed for same batch production

No material mix-up

Mold ready for Gratting fill-up

No mold damage

No bad surface finish allowed

Mold
50 preparation(Wax/rel
easer application)
No jam during release allowed

No visual damage allowed

Mold ready for Gratting fill-up

Formulation not followed

60 Slurry prepartion Forigen particels in the mixed resin

More/less slurry preparation

 roving lay-up as per the height requirment

Gratting Fill-up
70 Pressing as per the requiment of height
process

Resin puring asper the requirment

Hot water released to the mold

Curring
80 process(Cooling/heat
ing)
Cool water relesed to the mold

90 De molding Proper demolding (Without damage)

Without FPA production can not start

FPA procedure to be followed

100 FPA inspection Calibrated instruments to beused

100 FPA inspection

Part to be checked against the QAP requirment

Inprocess inspectionas per plan

Inprocess inspectionas per plan

110 Inprocess inspection

Part dimension asper drawing

Part colorLight gray(RAL-7035)

Part dimension asper drawing

 Finishing asper part drawing

120 Final inspection

Part colorLight gray(RAL-7035)

Ok testing as per the QAP

130 Packaging Packaging as per the sternderd

0
Sr. No. Rev. No. Revision description
1 R-0 Initial Release

Prepared By:
Mr.
 EPP Com
Process Failure m

Failure mode

Material : Resin
Grade :-Isophthalic polyester (FR Grade V1,UV)
different grade

Wrong invoice

Dust, dirt and contamination on material

Lot/Batch traceability missing

Over stacking of material bags/bins

Material received in damaged packaging (bags,

bin etc.)

Lot quantity and weight

Fork lift not available

Without IQC confirmation/uninspected material

move their final storage location

Low/high density @27 ℃

Less/more GELtime
Less Peak Exotherm

Test certificate verification

Acid Value Out Spec.

Less/more Viscocity @25 ℃

Material not stored in defined location

Material pick list not as per Work order

GRIN & LRN rejection mixed with ok material

Material is stroed wrong condition

Wrong format for label

Spilage of material

Self life not monitoring

FIFO not followed

Material loaded in wrong bin/dryer

Wrong materail loaded.

Wrong material issued

Less/more Qty. issued

Mix of batch/lot

Material mix-up

Mould reediness not done for gratting fillup

(Wax/releser application)

Mold damage

Bad surface finish

Jam during release

Visual damage

Mould reediness not done for gratting fillup

(Wax/releser application)

Correct formulation

No forigen particles allowed in the slurry

No more/less slurry preparation

roving lay-up not done as per height
requirmnet

No .of pressing not followed

Resin puring not done as per requirment

Hot water not released to the mold

Cool water not releassed to the mold

Proper demolding not done

FPA not followed

1. Procedure not followed

2. CP inspection frequency not followed

Uncelebrated instruments not taken back from

shop floor
Part not checked as per the QAP.

Inprocess inspectionskiped

Inprocess inspectionskiped

Part dimensions not as per drawing

Part color mismatch

Final part dimension as perdrawing

Finalpart finishing not ok

Part color mismatch

Part testing as per QAP

Packaging not as per the strnderd.

 EPP Composite Pvt. Ltd.
Process Failure mode and effect analysis

Classification
Sevirity

Effect Potential causes

Purchase order
CTQ

Part strength 0
not followed

Wrong material
wrong materail
send by supplier

Pacaging
procedure not
Contaminationon part
followed by the
supplier
Pacaging
procedure not
lack of tracebility on incoming material
followed by the
supplier
 No place decided
Seafty concerns
for RM storing

Pacaging
procedure not
material properties loss
followed by the
supplier

Less material
Material loss
supplied

Forklift maintance
Dealy in oprocessing
not done

material properties loss/chance of Procedure not

wrong product. followed

Wrong material
Product Non-complince
send by supplier

No defind location
Dealy in processing for material
storage
 Material pick list
not
wrong material followed,Incorrect
identification on
material

Product Non-complince

Product Non-complince

material eexpaired

Product Non-complince

Product Non-complince
Product Non-complince

on part demolding

Part charecterstics
Less in part height

Defect on part

Defect on part

Curing issue

Curing issue

Damage part/mold

NC part

NC part

NC part
NC part

NC part

NC part

NC part

NC part

NC part
NC part

NC part

NC part

Part damage
.
analysis

Original date:

5/26/2024

Revision No.

0.00

Revision date

5/26/2024
Occurance

Current Controls Recom

Detection
mande

RPN
Resp.
d
Process -
Detection actions
prevention

Material grade Verification of

described in the goods recevied by
PO the store

Verification of
Grn at the time
invoice with actual
of receving
RM

Feedback to
Visual verification
supplier for no
of RM
contaminted RM

Feedback to Visual verification

supplier for no of lot/batch
contaminted RM tracebility
Dedicated rack
Visual verification
for RM storing

Feedback to
Visual verification
supplier for no
of RM
contaminted RM

Vierification of QTY.
Qty. described in
at the time of
the PO
receving

Forklift
Maintance plan
maintance

IQC procudere OK sticker after IQC

for testing inspection

Raw material
Testing of raw
grade describe in
material at iqc
the PO.

Defined location
for material Visual verification
storage
Issunce of
Start-up inspection
material as per
and inprocess
the pick list,
inspection by
Material issue
quality for materil
slip to store for
used
correct material
 3 0

Approved By:
Mr.
 Action
results
Sevirity

Occurance

Detection

New RPN
3007
 EPP Composite Pvt. Ltd.
Process Failure mode and effect analysis

Product Name Original date:

Product Code Revision No.

Core team: Revision date

Characteristics Sample
Operation

CTQ
Op. No. Specification Method of checking Control method Reaction Plan
description No. of
Product Process Frequency
samples

Each Return goods to

Correct material As per purchase order Against PO Each receipt -
material supplier
Recipet of raw
material,packaging
10
material and bought Quantity As per invoice As per invoice Each receipt - - Intimate supplier
out
Free from damage,foreign Return goods to
Physical condition Visually Each receipt - -
contamination supplier

As per control plan /check sheet for raw material. LDPE (16MA400),LDPE (24FS040), TPR (3011), EVA (FL55F), PP (SRN100NC),
EVA(2518CO), MB-GRN-0614-MP, MB-RED-0823-MP, MB-1272, YLW-0548-MP

as per control plan /check sheet for Metal wire QC-F-39

Hold material and
20 Receiving inspection
intimate supplier
as per control plan / check sheet for SS tube - QC-F-10

as per control plan / check sheet for Metal wire - QC-F-39

Record in Hold produced

Issuance of Raw Each start-
30 Correct material as per BOM Visually - online material and stop
material up
inspection form production

Characteristics Sample
Operation
CTQ

Op. No. Specification Method of checking No. of Control method Reaction Plan
description Product Process Frequency
samples

Record in
As per Hold produced
online
Every 2 standard material from last
inspection
hours sampling inspection and stop
Molding process for format - QC-F-
plan production
stem green 49
40

Record in
As per Hold produced
online
Molding process for Every 2 standard material from last
50 inspection
flower pin holder hours sampling inspection and stop
format - QC-F-
plan production
49

Extrusion process
60
for Pink petals

Record in
As per Hold produced
online
Extrusion process Every 2 standard material from last
70 inspection
for Multi color leaf hours sampling inspection and stop
format - QC-F-
plan production
49

Record in
As per Hold produced
Printing process for online
Every 2 standard material from last
80 pink leaf and multi inspection
hours sampling inspection and stop
color leaf format - QC-F-
plan production
49

confidential information Page: 39 form no.NPD-04,

Rev.-00,Date-01/03/2021
 Every 2 standard material from last
80 pink leaf and multi inspection
hours sampling inspection and stop
color leaf format - QC-F-
plan production
49

Record in
As per Hold produced
Cutting process for online
Every 2 standard material from last
90 pink petals, Multi inspection
hours sampling inspection and stop
color leaf. format - QC-F-
plan production
49

confidential information Page: 40 form no.NPD-04,

Rev.-00,Date-01/03/2021
 Record in
As per Hold produced
online
Embossing process Every 2 standard material from last
100 inspection
for petals hours sampling inspection and stop
format - QC-F-
plan production
49

Record in
As per Hold produced
online
Back bone shotting Every 2 standard material from last
110 inspection
process hours sampling inspection and stop
format - QC-F-
plan production
49

Record in
As per Hold produced
online
Sub assembly Every 2 standard material from last
120 inspection
process hours sampling inspection and stop
format - QC-F-
plan production
49

confidential information Page: 41 form no.NPD-04,

Rev.-00,Date-01/03/2021
 format - QC-F-
plan production
49

As per Record in Hold produced

Every 2 standard Offline material from last
hours sampling inspection form inspection and stop
plan QC-F-32 production

Assembly process /
130
Packaging process

As per Record in Hold produced

Every 2 standard Offline material from last
hours sampling inspection form inspection and stop
plan QC-F-34 production

confidential information Page: 42 form no.NPD-04,

Rev.-00,Date-01/03/2021
 - - - Intimate material
140 Transfer to FG trsnsfer requester
- - - and hold transfer

Hold shipment and

product requirement inform logistics to
as per final inspection check sheet QC-F-194
Final inspection and fullfilment not ship it to
150 customer
dispatch
Reject container and
container inspection as per container inspection report - QCF41
inform logistics

Revision history:

Sr. No. Rev. No.

Revision description

1 R-0
Initial Release

Prepared By: Approved By:

Vishal Madankar Mr.Awadh kishor singh(D.Y. Manger).

confidential information Page: 43 form no.NPD-04,

Rev.-00,Date-01/03/2021