Kneader Process FMEA

S. Process No. Function (Step) Potential Failure Modes (process defects) (Y's) Potential Failure Effects (Y's)
S E V

Doc. No.:Annxure-2
D E T R P N Recommended Actions Responsible Person & Target Date Actions Taken S E V O C C

Potential Causes of Failure (X's)

O C C

Current Process Controls

1 Product will fail to meet specification of Product NC at 1.Hardness Homogenity Tensile Strength 5

Operator Judgement for homogenity

2 3 4 5 6 7 8 9 10

Kneading

5 5 5 5 5 5 5 5 5

Untrained man power

unaware of CTQ's unaware of proper mixing criteria unaware of receipe doesn't follow work instruction Improper pressure PM schedule not followed Improper water circulation work instruction not displayed illegible work instruction visual aids for homogenity not Not weigh as per receipe chart quality of RM wrong material used Improper Receipe

Receipe displayed, weighed and logged

30

30

3 3 2 3 2 2 2 3 2 2 3 3 2 3 2 Operator Trained & qualified

3 3 4 3 3 2 3 2 3 3 2 3 2 3 3

45 45 40 45 30 20 30 30 30 30 30 45 20 45 30

45 45 40 45 30 20 30 30 30 30 30 45 20 45 30

Operator Trained & qualified Preventive maintenance schedule not followed temperature indicator proper work instruction displayed proper work instruction displayed visual aids displayed receipe chart displayed tc identified each material receipe chart displayed

11 12 13 14 15 16

5 5 5 5 5 5

Kneader Process FMEA

D E T R P N

Doc. No.:Annxure-2

Process Potential Function Failure Modes (Step) (process defects) (Y's)

Potential Failure Effects (Y's)

S E V

Mixing Process FMEA O Potential Causes Current Process

of Failure (X's)
C C

Controls

D E T

R P N

Recommend Responsible ed Actions Person & Target Date

Actions Taken

S E V

O C C

1 Product NC at Homogenity Product will fail to meet specification of 1.Hardness 5

Operator Judgement for homogenity

Operator Trained & qualified Operator Trained & qualified Operator Trained & qualified Operator Trained & qualified Operator Trained & qualified Operator Trained & qualified Preventive maintenance schedule followed Teperature indicator work instruction displayed legible work instruction displayed visual aids for homogenity displayed weighed as per receipe chart Test certificate identified each material proper receipe chart displayed identified each material

30

2 3 4

Mixing

5 5 5

Untrained man power

unaware of CTQ's unaware of proper mixing criteria unaware of receipe doesn't follow work instruction Improper pressure PM schedule not followed Improper water circulation work instruction not displayed illegible work instruction visual aids for homogenity not displayed Not weigh as per receipe chart quality of RM wrong material used Improper Receipe chart Improper identification

3 2 2 3 2 3 2 2 2 2 3 3 2 2 2 2

3 2 4 3 3 3 2 2 3 3 3 3 2 2 3 3

45 20 40 45 30 45 20 20 30 30 45 45 20 20 30 30

Tensile Strength

5 6 7 8 9 10 11 12

5 5 5 5 5 5 5 5

13 14 15 16 17

5 5 5 5 5

Mixing Process FMEA

D E T

R P N

Mixing Process FMEA

# Process Functio n (Step)

Potential Failure Modes (process defects) (Y's)

Potential Failure Effects (Y's)

S E V

Potential Causes of Failure (X's)

Curing Process FMEA O

C C

Doc. No. Annxure-2

D E T R P N Recommen Responsibl Actions ded e Person & Taken Actions Target Date S E V O C C

Current Process Controls

1 Material is rejecteed/regraded at hardness and tensile strength 6

Unawrae of setup instruction untrained man power unaware of working procedure PM schedule not followed Pressure Gauge not working temperature indicator & controller not working
Leakage in machine Blockage of pipe improper set up

Manpower Trained & qualified Manpower Trained & qualified Manpower Trained & qualified Preventive maintenance schedule followed
Periodic inspection of Pressure gauge with PM

54

45

3 6 4 Curing 5 6 7 8 9 10 11 12 13 14 15 16 17 Product is over cured/under Material is reworked cured at hardness 5 5 5 5 5 5 5 5 5 5 5 5 5 5

2 3 3 3 3 2 3

4 3 3 3 3 3 4 3 3

48 45 45 45 45 30 60 30 45 30 30 30 30 45 45

Preventive maintenance schedule followed Preventive maintenance schedule followed Preventive maintenance schedule followed
trained man power about set up instruction Temperature indicator

temperature not reaching at 2 desired value use of wrong Die excess material used in block not defined set up instruction wrong material used receipe ratio Poor Gauge R&R poor instrument handling 3 3 3 3 3 3 3

material used as per receipe chart set up instruction defined and displayed identified material receipe chart displayed Gauge R&R Study Trained Man Power is Used

2 2 2 2 3 3

18

uncalibrated instrument used

Curing Process FMEA

3 calibrated instrument used 3 45

Doc. No. Annxure-2

D E T

R P N

Curing Process FMEA

Doc. No. Annxure-2

Curing Process FMEA

Doc. No. Annxure-2

Cutting Process FMEA

# Process Potential Function Failure Modes (Step) (process defects) (Y's) Potential Failure Effects (Y's)
S E V

Doc.No:Annxure-2

Potential Causes of Failure (X's)

O C C

Current Process Controls

D E T

R P N

Recommen Responsible Actions ded Person & Taken Actions Target Date

S E V

O C C

1 2 3 Material rejected by customer

5 5

use of untrained man power doesnot follow work instruction] unaware of working procedure Low moral Improper setting

2 2

Trained manpower & qualified Trained manpower & qualified Trained manpower & qualified Trained manpower & qualified
Preventive maintenance schedule followed Preventive maintenance schedule followed Preventive maintenance schedule followed Preventive maintenance schedule followed W.I. for set up being used displayed & revieved Trained manpower & qualified calibrated instrument used Inspect and inform to maintenance dept.

4 3

40 30

5 4 Slicing 5 6 5 7 5 8 9 10 11 12 13 14 15 5 Product sliced at NC thickness Material reworked/ Regraded

30

5 5

4 3 3

3 3 3

60 45 45

PM schedule not followed

unstable machine

30

5 5 5 5 5 5 5

not specialised not defined set up instruction work instruction not displayed poor instrument handling uncalibrated instrument used rough tool used hard material improper measuring instrument

3 3 3 3 3 3 3

2 3 3 2 3 3 3

30 45 45 30 45 45 45

1. calibrated Gauge used 2. Gauge R&R done 3. Periodic inspection is done for thickness

45

Cutting Process FMEA

D E T R P N

Doc.No:Annxure-2

FMEA for Curing Process

# Process Potential Potential Function Failure Modes Failure (Step) (process Effects (Y's) defects) (Y's)
Curing Variation in Thickness,Hard ness Material is rejecteed/ regraded at thickness Material is rejected due to air bubble S E V

Potential Causes of Failure (X's)

O C C

Current Process Controls

D E T

R P N

Recomme Responsi Actions nded ble Taken Actions Person & Target Date

S E V

O C C

6 7 8 8 8 8 8 6 6 7 7 6 8 8 7 7 7 6 6 8

Unawareness of setup instruction

5 5 4 6 5 6 6 7 5 6 5 6 6 4 5 4 4 3 4 5

Train & Qualified operators Train & Qualified operators Train & Qualified operators Follow PM shedule Follow PM shedule Follow PM shedule clean and maintain the intrument Temperature indicator,pressure gauge Temperature indicator size of component display die list with no. and size Display working instruction weigh as per receipe chart Use as per requirement identify each material Display receipe chart Train & Qualify operators Train & Qualify operators Use calibrated instrument

3 4 4 3 4 3 2 3 2 2 4 4 3 4 3 3 4 3 4 5

90 140 128 144 160 144 96 126 60 84 140 144 144 128 105 84 112 54 96 200

Use of untrained manpower

Unawareness of working instruction Temperature,pressure indicator not working PM schedule not followed Improper working of hydraulic pump Instrument showing illegible reading Insufficient temp. and pressure at machine Blockage of pipe lines Faulty Heater Unequal cavity space in mould Use of wrong Die Working Instruction not displayed Not weigh as per receipe chart Excess material used in mould Wrong material used Ratio of Receipe Poor gauge R & R Poor instrument handling Uncalibrated instrument used

Air bubble in component

FMEA for Curing Process

D E T R P N

Process Potential Failure Function Modes (process (Step) defects) (Y's)

Potential Failure Effects (Y's)

S E V

Potential Causes of Failure (X's)

O C C

Current Process Controls

D E T

R P N

Recommen Responsibl ded e Person & Actions Target Date

Actions Taken

S E V

O C C

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Punching Product NC at Dimension 1. Material rejected by customer. 2. Material reworked/regraded. Use of wrong tool 4 3

Tool identified & tooling management system is in place First & last piece inspection is done First piece inspection is done 3 36

Use of blunt/tool/Die

Improper set up

D E T

R P N

FMEA KNEADER MACHINE CAUSES Untrained man power

unaware of CTQ's unaware of receipe Not weigh as per receipe chart wrong material used unaware of proper mixing criteria Operator Judgement for homogenity doesn't follow work instruction PM schedule not followed Improper water circulation work instruction not displayed illegible work instruction visual aids for homogenity not displayed Improper Receipe Improper pressure quality of RM

RPN
45 45 45 45 45 40 30 30 30 30 30 30 30 30 20 20

Percent 8 8 8 8 8 7 6 6 6 6 6 6 6 6 4 4

Cum % 8 17 25 33 41 49 54 60 65 71 76 82 87 93 96 100

545

Pareto For Kneader FMEA

60 50 40

RPN

30 20 10 0

Series2, 4

Xs
45 8 17 45 8 25 45 8 33 45 8 41 40 7 49 30 6 54

Series1, 20

RPN Percent Cum %

45 8 8

30 6 60

30 6 65

30 6 71

30 6 76

30 6 82

30 6 87

30 6 93

20 4 96

20 4 100