Operation Product/Process

Operation Description Process Function PC ID S No. Product Process Potential Failure Mode Potential Effects of Failure: Sev Sev Potential Causes of Failure Occ Prevention Controls Detection Controls: Det Det
Number Specification/ Tolerance

OPN: Less/more
Incoming Quality
10.1 Incoming IQ/SS/PD/01 1 Viscosity of Varnish 30-35 sec Beyond spec consumption>>Physical inventory 7 Supplier process capability 1 Supplier Agreement Supplier Audit 7
Checking
dispatch
OPN: Defect skips in
IQC>Accumulation is more on
More 5
TFR>> Difficult in next process
during TFR clamp cleaning
OPN: Damage during
Stuffing of All component should have
transit>Rejection in full batch
IQ/SS/PD/02 2 components in properly mounted, no Not as per Specification 7 Supplier process capability 6 Supplier Agreement Supplier Audit 7
inspection>>Purchase return to
SMD PCBA slanting & no bending.
supplier
OPN: Defect skips in initial
5
testing>Rework
EU: Defect skips in all
checks>product reached to 7
customer >> functional issue
Component missing All required components OPN: Defect skips in initial
IQ/SS/PD/03 3 Not as per Specification 5 Supplier process capability 6 Supplier Agreement Supplier Audit 7
SMD PCBA should be present. testing>Rework
EU: Defect skips in all
checks>product reached to 7
customer >> functional issue
Polarity and All the seven segments OPN: Defect skips in initial
IQ/SS/PD/04 4 Not as per Specification 7 Supplier process capability 3 Supplier Agreement Supplier Audit 7
segment test need to work properly and testing>Rework
EU: Defect skips in all
4
checks>product reached to
IQ/SS/PD/05 5 Width of paper As per requirement Not as per Specification OPN: difficult to next process 2 Supplier process capability 1 Supplier Agreement Supplier Audit 7
IQ/SS/PD/06 6 Wattage of resistor As per specification More OPN: difficult to next process 2 Supplier process capability 1 Supplier Agreement Supplier Audit 7
EU: Defect skips in all
Less 7
checks>product reached to
OPN: Product fail in Visual Check by
IQ/SS/PD/07 7 Resistance As per the specification Not as per Specification 5 Wrongly validated by worker 1 Operator training 7
testing>Internal rework operator
EU: Defect skips in all
7
checks>product reached to
Wire color order of As per the specification on
IQ/SS/PD/08 8 Not as per Specification OPN: difficult to next process 2 Supplier process capability 2 Supplier Agreement Supplier Audit 7
10W 10P spox production manual of
EU: Defect skips in all
7
checks>product reached to
Print appearance of OPN: Damage during
IQ/SS/PD/09 9 At Part Specification Not as per Specification 5 Supplier process capability 5 Supplier Agreement Supplier Audit 7
carton transit>Rejection in full batch
IQ/SS/PD/10 10 TOP Dimension At Part Specification Not as per Specification OPN: difficult to next process 2 Supplier process capability 1 Supplier Agreement Supplier Audit 7
IQ/SS/PD/11 11 Flexibility of cable Cable should be flexible Not flexible OPN: Difficult to wire routing 2 Supplier process capability 1 Supplier Agreement Supplier Audit 7
Fitment of Can fix the cover with
IQ/SS/PD/12 12 Difficult to Fit OPN: difficult to next process 2 Supplier process capability 1 Supplier Agreement Supplier Audit 7
connector cover connector easily
Cap strength of Cap must be tightening OPN: Product fail in
IQ/SS/PD/13 13 Loose 5 Supplier process capability 2 Supplier Agreement Supplier Audit 7
fuse properly testing>Internal rework
EU: Defect skips in all
7
checks>product reached to
Centralized holes match
Hole Punching and
IQ/SS/PD/14 14 with components leads, No Not as per Specification OPN: difficult to next process 2 Supplier process capability 5 Supplier Agreement Supplier Audit 7
alignment of PCB
hole missing
OPN: Fails in HV test>Scrap
IQ/SS/PD/15 15 Class of Insulation Class F or Grade 2 in label Not as per Specification 8 Supplier process capability 1 Supplier Agreement Supplier Audit 7
generation
EU: Defect skips in all
checks>product reached to 8
customer >> Product failure
Thread / Head Correct threading. No
IQ/SS/PD/16 16 Not as per Specification OPN: difficult to next process 2 Supplier process capability 2 Supplier Agreement Supplier Audit 7
cutting of fasteners breakage, mismatching
OPN: Defect skips in IQC>Fails in
Fan should work in forward
IQ/SS/PD/17 17 Wire polarity of fan Not as per Specification initial test>>Rework/Scrap 8 Supplier process capability 1 Supplier Agreement Supplier Audit 7
biased condition only.
generation
EU: Defect skips in all
checks>product reached to 6
customer >> functional issue
OPN: Defect skips in IQC>Fails in
Fan Speed & Noise Fan should work without
IQ/SS/PD/18 18 Not as per Specification initial test>>Rework/Scrap 7 Supplier process capability 1 Supplier Agreement Supplier Audit 7
/ Vibration failing
generation
IQ/SS/PD/19 19 Fumes (solder flux) Fume should be less More S: Health issues of worker 1 Supplier process capability 1 Supplier Agreement Supplier Audit 7
OPN: Defect skips in initial
IQ/SS/PD/20 20 Brightness of LED Have good brightness Not as per Specification 5 Supplier process capability 2 Supplier Agreement Supplier Audit 7
testing>Rework
EU: Defect skips in all
checks>product reached to 7
customer >> functional issue
Insulation coating should
IQ/SS/PD/21 21 Insulation of Cable Not as per Specification OPN: Internal scrap generation 7 Supplier process capability 1 Supplier Agreement Supplier Audit 7
be uniform and centralized
Surface finishing Must be smooth and OPN: Defect skipped in initial
IQ/SS/PD/23 22 Not as per Specification 5 Supplier process capability 5 Supplier Agreement Supplier Audit 7
socket finishing checks>Internal rework
EU: Defect skipped in all
2
checks>>Aesthetic issues
Screw tightness of
IQ/SS/PD/24 23 Must be tight Loose OPN: Not in place>Internal rework 3 Supplier process capability 5 Supplier Agreement Supplier Audit 7
connector terminal
EU: Defect skipped in all
7 2 7
checks>Functional issues
Crimping
Must have fine crimping OPN: No continuity of earth ring>
IQ/SS/PD/25 24 perfection of Earth Loose 7 Supplier process capability 5 Supplier Agreement Supplier Audit 7
(not loosened) internal rework/scrap
ring connector
Solderability of Must have good
IQ/SS/PD/26 25 Not good solderability OPN: Difficult in process 2 Supplier process capability 2 Supplier Agreement Supplier Audit 7
leads solderability.
No blackening. Must have
IQ/SS/PD/27 26 Quality of leads Not good OPN: Difficult in process 2 Supplier process capability 2 Supplier Agreement Supplier Audit 7
good shining
No break of Insulation (no
continuity in the top and OPN: No load current is
IQ/SS/PD/28 27 Insulation Test of Lamination bottom surface). At edge Not as per Specification more>Internal rework/scrap 8 Supplier process capability 3 Supplier Agreement Supplier Audit 7
insulation is not generation
mandatory.
Runner
No projection on the
IQ/SS/PD/29 28 Portion/Projection Projection OPN: Difficult in process 2 Supplier process capability 7 Supplier Agreement Supplier Audit 7
runner portion.
of cabinet
Stapler Pin Quality No rust, shrinking ,stainless OPN: Material
IQ/SS/PD/30 29 Not as per Specification 7 Supplier process capability 5 Supplier Agreement Supplier Audit 7
Carton steel pins. rejection>Production delay
Scratches, burrs on OPN: Material
IQ/SS/PD/31 30 No Scratches, burrs, Scratches/Burrs 7 Supplier process capability 5 Supplier Agreement Supplier Audit 7
carton rejection>Production delay
Bending/ Shape No shape changing / OPN: Material
IQ/SS/PD/32 31 Shape changing/Bending 7 Supplier process capability 7 Supplier Agreement Supplier Audit 7
Change of Cabinet Bending. rejection>Production delay
IQ/SS/PD/33 32 Thickness At Part Specification Beyond specification OPN: difficult to next process 2 Supplier process capability 2 Supplier Agreement Supplier Audit 7
Type & Dimension
IQ/SS/PD/34 33 At Part Specification Beyond specification OPN: difficult to next process 2 Supplier process capability 2 Supplier Agreement Supplier Audit 7
Bobbin