C O D D

S L C E R Resp. & Target S O E R

Process function Potential Cause (s) Mechanism(s) Current Process Control Recommended Action C
Requirement Potential Failure Mode Potential Effect Of Failure E A C Current Process Control Detection T P Completion E T P
Requirement of Failure Prevention Action(s) Taken C
V S U E N Date V E N
S R C U C
R
>Identification missing on bags
Material receiving as per -Material grade not as per >Verified by store person during unloading of material
invoice invoice
-Production line may suffer 7 Normal >Material not verified with invoice during 2 WI for good receipt is in place.
check sheet
7 98 Nill
unloading

>Material bags & box damaged during >Unloading Method defined

Material packaging Material/parts May be >Quality inspector verify packaging during incoming
10 & Raw Material & Brass condition should be ok Material Box & Bags damaged. scrapped
7 Normal unloading-unloading method not defined. 2 >Packing Standard defined & agreed by
inspection
7 98 Nill
10A Insert M2.6 Receipt >packaging standard not defined. supplier

>No location defined for material

>Location identified for every grade
Material storage as per Material placed in unidentified Mixing of material with identification. >Store person verify the material storage as per
defined location location other grade
6 Normal
>Operator not aware about identified
2 material on Material Storage Board
defined location
7 84 Nill
>Trained IQC/Store person
location.

>Material received without verification

Correct Grade of >No awareness imparted to inspector/store
>Approved supplier
Material( PBT+PC - Wrong grade,properties/ person to verify grade >Supplier Material Test Certificate
>Trained IQC/Store person
( GF+GS) 40 specification of material parts will be scrapped 7 Normal >MTC not provided by supplier 2
for good receipt is in place at store.
>Incoming inspection report / GRN clearance through 4 56 Nill
(Polyplastics) / Black Received >Unapproved supplier SAP
>MTC along with material
Received >No Identification tag/print of grade on
material bag.
Incoming Inspection
20
( Raw material ) >Not verified during inspection >Incoming inspection standard
>Incoming inspection report/GRN clearance through
Damaged >Not verified during material issuance >Shelf life monitoring is in place
Material condition
expired material,Moisture
parts will be scrapped 7 Normal
Material bags damaged or open in storage
2
>Material bags condition checked during
SAP 4 56 Nill
>Monthly review of shelf life
location unloading.

>Specific inspection standard

>Identified visual ,Fitment & Functional
Testing parametrs of as material not per test MFI- >Trained Inspector >Material as per testing standard & Supplier PDI
per specification specification
parts will be scrapped 7 Normal defect not considered in inspection check 2
>Approved supplier & PPAP Conduct at report
5 70 Nill
sheet
suppleir end.

>Material received without verification

>No awareness imparted to inspector/store
>Approved supplier
Correct Grade of Wrong grade,properties/ person to verify grade >Supplier Material Test Certificate
>Trained IQC/Store person
Material Brass / Yellow ) specification of material parts will be scrapped 7 Normal >MTC not provided by supplier 2
for good receipt is in place at store.
>Incoming inspection report / GRN clearance through 4 56 Nill
Received Received >Unapproved supplier SAP
>MTC along with material
>No Identification tag/print of grade on
material bag.

>Not verified during inspection >Incoming inspection standard

Damaged >Not verified during material issuance >Shelf life monitoring is in place >Incoming inspection report/GRN clearance through
Material condition parts will be scrapped 7 Normal 2 4 56 Nill
Incoming Inspection material,Rust , Dust etc. Material bags damaged or open in storage >Material bags condition checked during SAP
20A location unloading.
( Brass Insert M2.6 )

> Minimum Skill level 3 inspector deputed > inspection done as per inspection standard at IQC
Insert Thread Miss/ >Part not check as per drawing
Part rejected at customer on receipt stage. level.
Profile should not be Insert Thread Miss / Damage
end / Line may suffer.
7 Normal requirements. 2
> Part check as per inspection plan and > Minimun Skill Level 3 Inspector on receipt stage.
5 70 Nill
Damage > Un Skilled Inspector .
standard. > Followed the sampling plan ( IM/QA/09)

>Identified visual ,Fitment & Functional >Specific inspection standard >As per testing standard & Supplier PDI report.
Dimension should be as Part not assembled at defect not considered in inspection check >Trained Inspector > Material inspection as per inspection report.(
per specification
Dimensions not as per drawing
assembly process
7 Normal
sheet.
2
>Approved supplier & PPAP Conduct at IM/QA/01)
5 70 Nill
> MTC not as per standard. suppleir end. > Receipt Inspection as per Inspection Std.

>No location defined for material

>Location identified for every grade
Material storage as per Material placed in unidentified Mixing of material with identification. >Store person verify the material storage as per
defined location location other grade
6 Normal
>Operator not aware about identified
2 material on Material Storage Board
defined location.
7 84 Nill
>Trained IQC/Store person
location.

Mixing of material with > Operator not aware about FIFO. > Store Engineer verify material on daily basis.
Material storage as per > Trained Operator at storage location.
FIFO system
FIFO not followed. different same grade 6 Normal > FIFO not followed by Operator. 2
> FIFO WI displayed at location.
> Training to store person as per plan. 7 84 Nill
Storage of raw material > FIFO borad not maintened. > FIFO controlled by SAP.
30 &
material & Brass
30A
Insert M2.6 Material / chemical self > Self life of material / chemical not > Material self line monitor as per
life should not be expired
Material self life expired. parts will be scrapped 7 Normal
mainten on daily basis.
2
mentioned on checmical drums/bottels.
> Self life control through the SAP system. 3 42 Nill

>No location defined for material

Mixing of material with
Indentification of RM as identification. > Training provided for person as per plan.
per grade
Wrong identification on bag other grade. 5 Normal
>Operator not aware about Identification
2 >Trained IQC/Store person
> Identification tag on RM bags/box.
6 60 Nill
Prod. Line may suffer
tag
 C O D D
S L C E R Resp. & Target S O E R
Process function Potential Cause (s) Mechanism(s) Current Process Control Recommended Action C
Requirement Potential Failure Mode Potential Effect Of Failure E A C Current Process Control Detection T P Completion E T P
Requirement of Failure Prevention Action(s) Taken C
V S U E N Date V E N
S R C U C
R

Raw Material & Brass >No location defined for material > Material as per planning sheet.
> Store person verify material bag tag with planning
40 & Correct material issue to Wrong material issurance from identification. > SAP grade and material bag Tag match.
Insert M2.6 Issue production. RM store
parts will be scrapped 7 Normal
>Identification tag wrong on bags.
2
> material issue through SAP reservation
sheet. 4 56 Nill
40A >RM issued as per SAP reservation Slip.
Prod. > material reservation slip not followed. Slip.

>Digital Display show the preheating

>Operator recorded Process parameter in Process
>Wrong Temperature setting temperature
Silver Line/glass mark Parameter sheet.
>operator not trained >Machine PM frequency defined
Preheating temp less/ More (Moisture) creation on the 4 Normal
>Heater malfunctioning
2
>Moisture content parameter covered in
> Re-Verification by LQA & Production Engineer 4 32 Nill
Surface of the Part. >MTC verified
>Moisture in material MTC
Material Preheating temp > M/C PLC controlled.
>Operation Standard defined
& Time as per
specification
Colour Variation , Poor >Wrong Parameter setting >Digital Display show the preheating > Operator recorded Process parameter in Process
Appearance , Part Rejected >operator not trained temperature Parameter sheet.
Preheating Time Less / More
& material jam in hopper or
7 Normal
>Heater malfunctioning
2
>Machine PM frequency defined > Re-Verification by LQC & Production Engineer.
6 84 Nill
Raw Material oven. >Preheating Temp. Not freezed. >Operation Standard defined > Record in material Pre-Heating Register.
50
Preheating
> Material issue throught the material issue
> Material issue from the SAP as per material
Right material load on Wrong material load in > Material issue system not followed. slip.
Machine. machine Hopper
parts will be scrapped 7 Normal
> Material not punch in SAP
2
> issue slip reverify & singed by the shift
mention in BOM. 4 56 Nill
> Reservation Issue Slip.
engineer.

> Clenaning of hopper properly check on check by

No other materpial resin
Colour Variation , Poor > Material cleaning process not followed shift supervisor & record in Mold Loading / Unloading
contamination mixed other material contaminiation > Material clean properly by Shift
with the other material in mixed with other material
Appearance , Part Rejected 7 Normal by operator during start up and change 2
supervisor by air gun.
sheet. 7 98 Nill
. over > Machine start up WI displayed for cleaning of
Hopper
Hopper.

> Re-Verification by LQC & Production Engineer

6 Normal >High injection pressure 2 > First/Last Part Approval by LQC Engineer . 4 48 Nill
> Machine Parameter PLC control.

> Shot weight setting as per Operation standard .

>Re-Verification by LQC & Production Engineer
6 Normal >Excess Shot Weight 2
> First/Last Part Approval by LQC Engineer .
4 48 Nill
> Machine Parameter PLC Control.
>Process parameter freezed & set as per
operation standard >Barrel temp. setting as per Operation standard .
WI for visual defects > Re-Verification by LQC & Production Engineer
6 Normal >Excess Barrel Temp. 2
> First/Last Part Approval by LQC Engineer .
4 48 Nill
> Machine Parameter PLC Control.

> Process parameter setting as per Operation

standard .
6 Normal >Wrong parameter setting at start up 2
> Re-Verification by LQC & Production Engineer
5 60 Nill
Insert Injection
> First/Last Part Approval by LQC Engineer .
Moulding / Cooling &
No Flash , Burr & Problem in Fitment at Assy
60 FPA/LPA & Inprocess Scratch Allowed
Flash , Burr & Scratch on parts
Line and at customer end
Inspection > Process parameter setting as per Operation
PM of machine standard .
6 Normal >Machine parameters malfunctioning 2
> Re-Verification by LQC & Production Engineer
5 60 Nill
> First/Last Part Approval by LQC Engineer .

6 Normal >Mould life over 2 >Shot monitoring and total shot decide >Mould history card maintain on daily basis. 6 72 Nill

> Process parameter setting as per Operation

standard .
>Process parameter freezed & set as per
6 Normal >Mould Clamping pressure less 2
operation standard
> Re-Verification by PQA & Production Engineer 4 48 Nill
> First/Last Part Approval by LQC Engineer .
> Machine Parameter PLC Control

>First/Last part approval by LQC Engineer.

> Visual inspection of parts.
6 Normal >Wear and tear in the mould 2 >Preventive Maintenance of the mould > Preventive maintenance of mould as per schedule. 6 72 Nill
> Charging position checked and recorded during
start of production .
 C O D D
S L C E R Resp. & Target S O E R
Process function Potential Cause (s) Mechanism(s) Current Process Control Recommended Action C
Requirement Potential Failure Mode Potential Effect Of Failure E A C Current Process Control Detection T P Completion E T P
Requirement of Failure Prevention Action(s) Taken C
V S U E N Date V E N
S R C U C
R
>First/Last part approval by LQC Engineer.
> Visual inspection of parts.
7 Normal >Wear and tear in the mould 2 > Preventive maintenance of mould as per schedule. 7 98 Nill
> Charging position checked and recorded during
start of production .
No Short Filling / Short
Short Filling / Short Mould /
Mould / Tool Problem in Fitment at Assy >Process parameter freezed & set as per > Shot weight setting as per Operation standard .
Tool Deformation Mark ,
Deformation Mark , Line and part reject & operation standard >Re-Verification by LQC & Production Engineer
Flash / Scratch / Dent /
Flash / Scratch / Dent / Stain
Appearnce NG
7 Normal >Less shot weight 2
WI for visual defects > First/Last Part Approval by LQC Engineer .
4 56 Nill
& crack.
Stain & crack. > Machine Parameter PLC Control.
> injection barrel temp checked and recorded during
start of production.
7 Normal >Low barrel temperature 2
> FirstLast Part approval LQC Engineer.
4 56 Nill
> Machine Parameter PLC Control.
> injection pressure checked and recorded during
start of production.
7 Normal >Less injection pressure 2
> FirstLast Part approval LQC Engineer.
4 56 Nill
> Machine Parameter PLC Control.
> Shot weight setting as per Operation standard .
>Process parameter freezed & set as per
>Re-Verification by LQC & Production Engineer
7 Normal >Less shot weight 2 operation standard
> First/Last Part Approval by LQC Engineer .
4 56 Nill
> Fitment NG at customer WI for visual defects
end > Machine Parameter PLC Control.
Insert Injection No Shrinkage/Warpage Shrinkage/Warpage
> Non fulfill of customer >Temp. checked and recorded during start of
Moulding / Cooling & requirment. production .
> part reject ,Appearnce 7 Normal >Low barrel temperature 2
> First Part Approval.
4 56 Nill
60 FPA/LPA & Inprocess NG > Machine Parameter PLC Control.
Inspection
> Fixture handoverd to production team as per
> Fixture impleted and trained manpower internal system.
deputed on machine Skill Level 3. > Trained manpower deputed skilllevel 3.
7 Normal > Part not cooled with fixture 2
> Fixture checked by senior person during > Cooling fixture conditon check on regular interval.
7 98 Nill
initial producton start up on machine. > FPA /LPA & In process Inspection as per sampling
plan.

> Process Parameter setting and recorded during

No Flow mark Part / >Preheating of raw material prior to start of
Flow mark Part / White mark / start of production
White mark /
Discoloration
Appearnce NG 5 Normal >Preheating not proper of raw material 2 production
> First/Last part Approval by LQC Engineer.
7 70 Nill
Discoloration WI for visual defects
> Parameter verification on regular basis.

> barrel temp checked and recorded during start of

>Process parameter freezed & set as per production
7 Normal >barrel temp high 2 operation standard > First/Last Part Approval by LQC Engineer. 4 56 Nill
WI for visual defects >100% Inspection of parts.
> Machine Parameter PLC Control.
Appearnce NG/Material
No Burning Mark Burning mark
property may degrade
> First / Last Part Approval by LQC Engineer.
>Purging of material befotre start of
>Inprocess petroling inspection
7 Normal >Material degrade in barrel 2 production (if production stop for a long
>Match production report vs Purged material qty.
4 56 Nill
time.
> M/c cycle time control by PLC control.
 C O D D
S L C E R Resp. & Target S O E R
Process function Potential Cause (s) Mechanism(s) Current Process Control Recommended Action C
Requirement Potential Failure Mode Potential Effect Of Failure E A C Current Process Control Detection T P Completion E T P
Requirement of Failure Prevention Action(s) Taken C
V S U E N Date V E N
S R C U C
R
> Fixture handoverd to production team as per
> Inspection skipped during production.
> Fixture impleted and trained manpower internal system.
> Untrained manpower for operator /
Part Should be cooled Apperance NG / Dimension deputed on machine Skill Level 3. > Trained manpower deputed skilllevel 3.
with Fixture.
Skilled Part cooling with fixture.
NG
7 Normal Inspector. 2
> Fixture checked by senior person during > Cooling fixture conditon check on regular interval.
7 98 Nill
> Cooling fixture not in use.
initial producton start up on machine. > FPA /LPA & In process Inspection as per sampling
> Cooling fixture damage/
plan.
> Part machine matrix not made. > Part load on machine as per define machine
> Part mold load on machine as per plan.
> prod. Plan not followed. tonnage in PPS.
M/c Selection as per M/c Tonnage not as per define Appearnce NG/Material > Mold / Machine matrix made for prod.
standard standard. property may degrade
7 Normal > Untrained Prod. Shift incharge. 2
Running parts.
> Reverify the shift incharge. 7 98 Nill
> Machine tonnage not define in PPS of > Training of operatr / shift supervisor as per plan.
> Machine tonnage define in PPS of part.
parts. > Mold load on machine as per matrix.
> Clamp force set at the mold set up on
> Clamp force not validiate at the time
Clamping Force as per machine of every set up. > Part FPA/LPA approval by LQC team.
specification
Clamping force low or High Part Appearnce NG 5 Normal mold setup on machine. 2
> Minimum skilled level 3 operator deputed > Minimum Skill level operator / inspector level 3.
5 50 Nill
> Un trained machine Operator.
on machine.

> Mold not fit in the Machine by fitment of

Proper position of mold Part Appearnce NG , Mold > Mold fit the machine with the machine > Mold set up by the shift supervisor.
clamp.
Improper Mold Clamp Position
may be damage.
6 Normal machine loacating ring. 2
loacating ring. > FPA/LPA approve by the LQC team.
5 60 Nill
Insert Injection > Untrained Operator for mold set up.
Moulding / Cooling &
60 FPA/LPA & Inprocess Cstomer line may > Mold load on machine not as per plan. > Mold load on machine as per plan. Reverify the mold plan by shift supervisor.
Inspection Correct mold setup Incorrect mold set up
suffer/decreased line speed
5 Normal
> Mold / maachine matrix not followed.
2
> Mold/ machine matrix followed. > Identification Available on mold.
7 70 Nill
> Mold not fit in the Machine by fitment of
Correct alingnment of Misalignment of the nozzle Part Appearnce NG ,Shot > Mold fit the machine with the machine > Mold set up by the shift supervisor.
Nozzle with the tool with the tool molding .
7 Normal machine loacating ring. 2
loacating ring. > FPA/LPA approve by the LQC team.
5 70 Nill
> Untrained Operator for mold set up.
> Machine parameter not set as per part > Parameter set by the shift supervisor as > Machine parameter check by the LQC inspector as
Incorrect mold temperature
Temp. of mold as per Part Appearnce NG. / Part PPS sheet. per part PPS. recorded in process control chart sheet.
PPS
(cooling lines misrouted,
reject at Inspection.
6 Normal
> Untrained operator for machine paraeter
2
> Skill level minimum 3 operator deputed >FPA/LPA approve by LQC team.
4 48 Nill
incorrect MTC settings,
set up. on machine > Mold Temp PLC Control.
No contamination , no > Mold set up by the shift supervisor.
blocking of cooling lines , > mold cooling line / MTC not check during > Mold check by shfit supervisor on > Mold check by the supervisor before load on the
contaminated /blocked cooling Part Appearnce NG. / Part
incorrect MTC
lines, improper cycle time), reject at Inspection.
5 Normal the mold set up on machine. 3 visually for mold readiness. machne visually. 4 60 Nill
settings ,proper cycle > Mold cooling not PM not done. >Mold PM as per define plan / frequency. > Cycle time and cooling system controlled by M/c
time as PPS. PLC .
> It is controlled by the machine poka yoke
> Operator delay the cycle time during Part FPA/LPA approval from the LQC team.
No material Hold too Holding material for too long in Material Burned in Barrel PLC control.
long time in barrel barrel and chocked.
7 Normal mold unloanding. 2
> Purging done for every start up machine
> Cycle time controlled by the machine Poka yoke 4 56 Nill
> During machine start up. PLC controlled.
delay more thean 10 minutes.
> It is ctrolled from initial design phase.
gate squencing / Incorrect gate sequencing / Part Appearnce NG. / Part > gate Squencing not define in mold at the > Mold gate squencing define during mold
balncing must be correct. balancing the cavities,etc.) , reject at Inspection.
6 Normal
mold manufacturing.
2
design phase.
> Visually check the gate point condition by prod. 4 48 Nill
Operator / supervisor.
 C O D D
S L C E R Resp. & Target S O E R
Process function Potential Cause (s) Mechanism(s) Current Process Control Recommended Action C
Requirement Potential Failure Mode Potential Effect Of Failure E A C Current Process Control Detection T P Completion E T P
Requirement of Failure Prevention Action(s) Taken C
V S U E N Date V E N
S R C U C
R
>Skilled Oprator deputed Level-3
>Opeartor not trained >Provide the training to operator about the
Fitment of brass insert Brass insert fitment not as per Part Fitment NG 7 2 >First/Last part approval and PDI report.
should be correct specification Functional Failure
Normal > Wrong method followed by operator part inserting process .
( IM/QA/23)
7 98 Nill
during inserting in mould . > Display the work instruction.
>inprocess petroling inspection. ( IM/QA/05)

Incorrect mould opening >Mold Opening and Ejection squencing

> Mold Opening and Ejection squencing > FPA/LPA approval from the LQC team.
Mold Opening process , process (opens too fast, process validiate at the time every mold
Part Appearnce NG. / Part process not validiate at the time mold > regularly check the mold opening or Ejection
Ejection Squencing overpacked, erratic motion,
reject at Inspection.
5 Normal
setup on machine.
2 setup on machine.
squencing by the machine operator.
5 50 Nill
should be correct. etc.),Incorrect ejection > Skill level minimum 3 deputed operator
> Un trained machine Operator. > Training as per plan for operator / inspector.
sequencing, on machine.

Cavity/Material Mark./ Calender marking/ Cavity > Part marking check by prod. Supervisor
> Part marking missed in the mold. > Visually check the LQC team at the FPA / LPA
Date,Month & Year maring, Material Marking & Lot identify very defficulty , during mold load on machine visually.
6 Normal > Part marking damage during running 2 approval. 8 96 Nill
Insert Injection marking & HONDA Mark HONDA Marking miss or Appreance NG
production.
> Abnormality rule difned for any
> Abnormality handling rule define at shop floor.
Moulding / Cooling & must be availabe on part change skipped, abnormality raise during working.
60 FPA/LPA & Inprocess
Inspection
First Part Inspection and
Part Approval should not > Machine run the prod. After approval > FPA/LPA approval from the LQC team.
approval (Setting > Inspector not aware about the part
be skipped during Part rejected at customer from quality LQC team. > Inprocess inspection every 4 hours.
machine startup/ change
Approval)First piece validation
end / Line may suffer.
5 Normal Approval at the mold runing on machine. 2
> Minimum skill level 3 Inspector deputed > Training as per plan for operator / inspector.
5 50 Nill
skipped, Last piece validation > Inspector negligency during mold set up.
over. on machine. > M/c run as per production plan.
skipped.

>Machine not operate as per operation

standard, mould pin wear out. >Mould preventive maintenance as per
>Opeartor not trained decide frequency & check for cooling
Dimension should be as Dimensions Less /More / not Part Fitment NG 7 2
per specification as per Spec Functional Failure * process parameter not followed
Mould Temperature high due to wrong
channel descaling frequency.
>Machine run as per defined process
>Part check in inprocess
First part approval and PDI report.
5 70 Nill
looping of water pipeline or scaling in parameter
mould .

>Untrained manpower deployed for

6 Normal
inspection
2 >Manpower as per skill matrix >Operator initials tag on Bin after 100% inspection 8 96 Nill

6 Normal >WIS not clear to the operator 2 >Training of operator as per plan >Effectiveness monitoring of operator through test 8 96 Nill
Fitment Failure/Part will be
Inspection not done
rejected
5 Normal >Low illumination at inspection area 2 >Proper lighting at inspection table >Lux level monitoring on regular basis 7 70 Nill

>Appraiser variation high and NG part >Training of operators for inspection by

5 Normal
flown out.
2
limit samples
>Regular R&R study of operators 5 50 Nill

> Inspector check the part as per frequency defined.

Parts not checked at Part Rejected at customer > Part checked by Un trained inspector > Trained Inspector deputed on inspector > Part inspection frequency check by shift engineer.
determined frequencies end
5 Normal
and not aware about frequency.
3
minimum Skill level 3. > Dock / Product audit done as per plan.
6 90 Nill
Visual Inspection as
70 Final Inspection per specifications
> Training of inspector as per plan.

> Untrained inspector deputed for part > Trained Inspector deputed on inspector
> Inspector check the part as per frequency defined.
Parts not measured at the right Inspection. minimum Skill level 3.
Part Rejected at customer > Dock / Product audit done as per plan.
location & not checked with
end
5 Normal > Receiving gauge identification not 2 > Receiving gauge kept define location.
> Training of inspector as per plan.
7 70 Nill
right gauge , avaialbe. > Identification tag of every gauge/Jig
> validation of gauges as per plan.
> Gauge kept on wrong palaces. available.

Part free from appreance

defect i.e. dent , scratches ,
Burn Mark Flash ,Sink Mark , >'> Trained Inspector deputed on inspector > Inspector check the part as per frequency defined.
Warpage ,tool depression Part Rejected at customer > Part inspected by un trained inspector. minimum Skill level 3. > Dock / Product audit done as per plan.
mark , flow mark , Oil mark , end.
6 Normal
> Part Inspection not done as per WI
2
> Part check by Inspector as per WI > Training of inspector as per plan.
7 84 Nill
Burr , Strain , displayed. > Final Inspection WI displayed at work instruction.
Deformation ,discoloration
etc .
 C O D D
S L C E R Resp. & Target S O E R
Process function Potential Cause (s) Mechanism(s) Current Process Control Recommended Action C
Requirement Potential Failure Mode Potential Effect Of Failure E A C Current Process Control Detection T P Completion E T P
Requirement of Failure Prevention Action(s) Taken C
V S U E N Date V E N
S R C U C
R
>Identical and single type of bins used for >PDI Inspection is in place.
Wrong Bin / Box Used 5 Normal >Packing standard not followed 2
all shafts > packing as per define standard.
5 50 Nill

>Work Order Provided and tag attached with checked lot

Mix up of Part Cstomer line may 5 Normal >No / Improper tag identification 2 > Operator training
and QA stamp on Bins/Box.
7 70 Nill
suffer/decreased line speed
>Dock audit as per plan.
>Identification tags not available Similar or >Identification system in place.
Wrong Part Pack 5 Normal
identical part nos.operator skill.
2
Packing standards available.
> Packing standard followed. 6 60 Nill
> Training as per plan.

> Part packed as per define packing

Part Rejected at customer > Part packed by untrained operator. stadanrd. > Part Packing reverify by quality inspector and paste
Dirty part packed
end
6 Normal
> Packing standard not followed.
2
> Part checked by Operator before packing identfication tag on Box.
8 96 Nill
in BOX/BIN.

80 Packing & Labeling As per Packing Standard > Part Quantity packed as per define
Cstomer line may > Part packed by untrained operator. packing standard. > Part Packing reverify by quality inspector and paste
Less / Excess quantity.
suffer/decreased line speed
5 Normal
> Packing standard not followed.
2
> Trainined operator deputed on material identfication tag on Box.
8 80 Nill
packing stage.

> Part packed by untrained operator.

Part Rejected at customer > Packing standard not followed. > Material Packed as define packing > Part Packing reverify by quality inspector and paste
No Foam bag used
end
6 Normal
> Foam sheet not availabe in stock for
2
standard by operator. identfication tag on Box.
8 96 Nill
packing.

> Part packed by untrained operator.

Part Rejected at customer > Material Packed as define packing > Part Packing reverify by quality inspector and paste
Partition tray not in places
end
6 Normal > Packing standard not followed. 2
standard by operator. identfication tag on Box.
8 96 Nill
> Partition of tray not availabe in stock.

Internal packaging incorrectly Cstomer line may > Part packed by untrained operator. > Material Packed as define packing > Part Packing reverify by quality inspector and paste
placed suffer/decreased line speed
5 Normal
> Packing standard not followed.
2
standard by operator. identfication tag on Box.
8 80 Nill

>Improper packing and covering of >Proper packing & storing of RM in >All material is checked by supervisior during
Storing & issuing Dust may be come 4 Normal
material
2
storage area receiving of material
7 56 Nill
Cstomer line may
material in good
suffer/decreased line speed
condition. Material may damage during >Improper identification and storage
handling
5 Normal
location
2 >Identification through status tag. >100% visual inspection during storage 8 80 Nill

Pre Dispatch
90 >Machine not operate as per operation
Inspection (PDI) standard, mould pin wear out. >Mould preventive maintenance as per
Dimension should be as >Opeartor not trained decide frequency & check for cooling >Part check in inprocess
Dimensions Less / More / not Part Fitment NG 7 2
per specification / Insp.
Std
as per Spec / Std Functional Failure * process parameter not followed
Mould Temperature high due to wrong
channel descaling frequency.
>Machine run as per defined process
>First/Last part approval and PDI report.
> Training to operator as per plan.
5 70 Nill
looping of water pipeline or scaling in parameter > Machine parameter monitoring Every 4 Hours
mould .

>Non availability of Pre-Dispatch >PDIR inspection standards in place

Inspect PDI material as >Material is checked as per Pre -Dispatch Inspection
per Standard
Passing wrong material Material Danage 5 Normal inspection standards 2 Identification W.I available. Sampling Plan
standard & tagged with appropriate label.
6 60 Nill
Material not identified properly. available
100 Material Storage
Mixing of material with > Operator not aware about FIFO.
Material storage as per > Trained Operator at storage location. > Store Engineer verify material on daily basis.
FIFO system
FIFO not followed. different same model 6 Normal > FIFO not followed by Operator. 2
> FIFO WI displayed at location. > Training to store person as per plan.
7 84 Nill
material > FIFO borad not maintened.

>Wrong labeling >Part wise Packing standard available.

>Material issued in FIFO order as per Identification
Identification tag correct. Identification NG 5 Normal > FIFO system not followed. 2 >Material identification system available.
tags.
5 50 Nill
>Customer dissatisfaction. >FIFO System in place

Quantity as per shipment >WI for keeping desired number of parts in

plan
Less / Excess quantity. 5 Normal >Packing standard not followed 2
the bin (as packing standard)
>Packing standard / PDI Inspection as per standard. 7 70 Nill
Cstomer line may
110 Dispatch suffer/decreased line speed > Part packing reverify by the dispatch >packing check by the store supervisor during
No Packaging damage Damage packing 5 Normal >Packing standard not followed 2
enginner visually during shipment shipment.
7 70 Nill

Invoice of material as per > Shipment plan not followed. > Plan review throught the SAP/mail and than after
shipment plan
Wrong inivoice 5 Normal
> Wrong shipment plan followed.
2 > Dispatch the part as per plan
make the invoice for material shipment.
5 50 Nill

No mix up parts with Route card system followed throughout the >PDI Inspection is in place.
other model parts
Model mix-up 5 Normal >Material descipline at FG 2
process > Daily production report.
5 50 Nill

RPN Action: The action will be initiated for the RPN value ≥ 100 or Top 3 RPN values and if the severity 8 or above.

PREPARED BY: Vishwnath Singh CHECKED BY : Sukhbir singh APPROVED BY: Mr. Abhishek Goyal

IM/NPD/06/00