Document Number 1 ofQS/FM/2201

4
Failure Mode and Effects Analysis (Process FMEA) Rev. No. & Dated 14 / 01.03.2020
Page No.
Company Name Customer Name Subject Process Responsibility PFMEAStart Date 05.03.2012

Manufacturing Location Model Year / Program CFT/MDT/Core Team Confidential Level PFMEA Revision Date 01.03.2020

Structure Analysis Functional Analysis Failure Analysis Risk Analysis Optimization

1. Function of

Severity(S) of FE
2. Function of the

PFMEA Action

PFMEA Action
Occurrence (O)

Occurrence (O)
Characteristics

Characteristics
3.Process Work process item

Priority (AP)

Priority (AP)
Detection (D)

Detection(D)
1.Process Items 2.Process Steps process step and 3. Functional of the

Severity(S)
of FC/ FM
Element Function Failure Effects (FE) to the next Current Detection Target Status (Open, Action taken

Special

Special
of FC
System, Subsystem, Station number and product process work element Failure Mode (FM) Failure Cause (FC) of the work Current Prevention Prevention Responsible Completion
Man, Machine, of System, Sub higher level element and / or End controls (DC) of FC or Detection Action completion Completed, with pointer Remarks
Part element or Name of Focus characteristic and process of the process step element control (PC) of FC Action Person Name Date
Material, system, Part element user FM date Discarded) to evidence
Name of the process element ( Quantitative value characteristic
Environment etc. or Process
is optional)

Inner Diameter Man 1. In Plant 4 Inner Diameter Man

4 7 M
Part Element Rough Boring Man Cylinder Liner Setting Not entering on Expantion Under Size Skill&Improper Setting Training Provided 1
Mandrel at Rough CNC
Cylinder Liner 1B Operation Machine Providing Sliding Inspection Overload at Fine Boring Ope. Improper 1st. Peace Inspection SOP Control Plan
Method Surface to Piston Machine Tool Consumption more at Machine
Rings while Fine Boring
retaining Lubricant
Material within Taper Taper & Ovality is more at next Taper in the Machine PM 1
Ope.
Environment Vibration Vibration in Mchine PM 1
Speed 2. Ship To Plant Low Speed Program Control 1 Control Plan
Feed Nil Low Feed Program Control 1 Control Plan
Clamping Pressure High Clamping Pressure Lock System 1
Chuck Runout 3. End User Chuck Runout More 4 Check List
Method Nil Method
Selection of Boring Improper Selection of Boring Bar SOP 1
Rough & Finish Rough & Finish Catridge Diff. more SOP 1
Catridge Diff.
Tool Life Tool Wear & Tear Count & Buzzer 1
Calibration Uncalibrated History Card 1
Material Material
Hards High Hards Furnace Not Lift 1 Control Plan
Lancer will not Move for
coating
Material Allowance More Material Allowance SOP 1
Environment Environment

Man 1. In Plant 6 Inner Diameter Man 9 7 H

Setting Freely entering into the mandrill , over Size Skill&Improper Setting Training Provided 9
operator inconve nience & reject
at subsequent operations(NP)
Inspection Improper 1st. Peace Inspection SOP 2 Control Plan
Machine Machine
Taper Taper in the Machine PM 2
Vibration Vibration in Mchine PM 2
Speed 2. Ship To Plant High Speed Program Control 2 Control Plan
Feed Nil High Feed Program Control 2 Control Plan
Clamping Pressure High Clamping Pressure Lock System 2
Chuck Runout 3. End User Chuck Runout More Check List
Method Nil Method
Selection of Boring Improper Selection of Boring Bar SOP 2
Rough & Finish Rough & Finish Catridge Diff. more SOP 2
Catridge Diff.
Calibration Uncalibrated History Card 2
Material Material
Hards Low Hards Furnace Not Lift 2 Control Plan
Lancer will not Move for
coating
Material Allowance Less Material Allowance SOP 2
Environment Environment

Plateau Honing Inner Diameter Man 1. In Plant 4 Inner Diameter Man

3 9 L
15th. Operation Man Cylinder Liner No. of Strokes 100 % Rejection Over Size Selection of Strokes 3
Machine Providing Sliding Stroke Length Selection of Stroke Length 1
Method Surface to Piston Inspection 2. Ship To Plant Input Stock material Measuring 1
Rings while Before Loading at the time of
retaining Lubricant operation
Material within Setting of Gauge Loose answering at Piston Ring Bore gauge setting changing 1
Assembly
Bhaviour Loss of engine performance Attitude 1
Environment Setting Degradation of Engine Skill&Improper Setting 2
Machine Machine
Rotating Speed Spindle Rotating Speed Variation 1
Reciprocating Speed 3. End User Spindle Reciprocating Speed 1
Spindle Runout More Oil Consumption Spindle Run out 2
Clamping Pressure Lubrication Problem Clamping Pressure 2
Expantion Load No uniform cooling Unit Expansion Load 2
Bed Face Plate Loss of Power at end user Bed Face Plate Parallelism 1
Parallelism
Bed Guide ways Bed Guide ways Condition 1
Condition
Column Guide Ways Column Guide Ways Condition 1
Condition
Coolant Flow Rate of Coolant Flow 1
Vibration Vibration 3
Air Pressure Pressure Variation From Air 1
Compressor
Method Method
Fixture Mounting Fixture Centering 2
Fixture Top & Bottom Fixtures Bottom & Top Face 2
Face Parallelism
Fixture ID Fixture ID Size 2
 Document Number 2 ofQS/FM/2201
4
Failure Mode and Effects Analysis (Process FMEA) Rev. No. & Dated 14 / 01.03.2020
Page No.
Company Name Customer Name Subject Process Responsibility PFMEAStart Date 05.03.2012

Manufacturing Location Model Year / Program CFT/MDT/Core Team Confidential Level PFMEA Revision Date 01.03.2020

Structure Analysis Functional Analysis Failure Analysis Risk Analysis Optimization

1. Function of

Severity(S) of FE
2. Function of the

PFMEA Action

PFMEA Action
Occurrence (O)

Occurrence (O)
Characteristics

Characteristics
3.Process Work process item

Priority (AP)

Priority (AP)
Detection (D)

Detection(D)
1.Process Items 2.Process Steps process step and 3. Functional of the

Severity(S)
of FC/ FM
Element Function Failure Effects (FE) to the next Current Detection Target Status (Open, Action taken

Special

Special
of FC
System, Subsystem, Station number and product process work element Failure Mode (FM) Failure Cause (FC) of the work Current Prevention Prevention Responsible Completion
Man, Machine, of System, Sub higher level element and / or End controls (DC) of FC or Detection Action completion Completed, with pointer Remarks
Part element or Name of Focus characteristic and process of the process step element control (PC) of FC Action Person Name Date
Material, system, Part element user FM date Discarded) to evidence
Name of the process element ( Quantitative value characteristic
Environment etc. or Process
is optional)

Gauge Selection Gauge difference In Std Room & 1

Shop Floor.
Gauge Master Wrong Master used 1
Gauge Calibration Uncalibrated Gauge 1
Material Material
Hardness Liner hardness 1
Input allowance Casting Inner diameter more / less 2
Input allowance
Quality of Input ID size variation, Taper , 3
Concentricity & Surface Finish at
Fine boring & Rough Honing
OD size variation & Taper at CNC
Stick Selection & Wrong Stick Grade & Condition 1
Condition
Coolant Wrong Coolantmix 1
Honing Unit Honing Unit Condition 1
Coolant Filtration Honing machine coolant filteration 1
condition
Environment Environment
Atmospheric conditions Atmospheric conditions 1
Coolant Temp. Coolant Oil Temp. 1
Temparature Variation Temparature Variation between Std 1
Room & Shop Floor
Product Cylinder Liner 1. In Plant 0 #N/A
Assembly 100 % Rejection
Cyliner Liner
Assembly Proper fitment in
Cylinder Block

2. Ship To Plant
Loose / Tight answering at Piston
Ring Assembly
Reduce life of Pistion Ring
Improper seating in Engine Block
Sub System Engine Block More / Less clearence in Engine
Block
Engine Block Converts Chemical Loose / Tight seating of Gasket
Energy to Coolant Leakage into Crankcase
Mechanical Energy
Scratches in Engine Block
Loss of engine performance
Degradation of Engine
Performance
System Vehicle 3. End User

Vehicle Movement to Chance of Engine Seizure on the

Vehicle road
More Oil Consumption
Lubrication Problem
No uniform cooling
Unable to movement of Vehicle
Loss of Power at end user

Rev.No. Rev. Date Revision Detail

NN DD.MM.YYYY Updated w.r.t. AIAG-VDA 1st. Edition

Prepared
Prepared By Production Engineer (M)
By Director - Operations
Signature Signature

Date Date
 Document Number 3QS/FM/
of 4
Failure Mode and Effects Analysis (Process FMEA) Rev. No. & Dated
Page No.
Company Name Customer Name Subject Process Responsibility PFMEAStart Date

Manufacturing Location Model Year / Program CFT/MDT/Core Team Confidential Level PFMEA Revision Date

Structure Analysis Functional Analysis Failure Analysis Risk Analysis Optimization

1. Function of

Severity(S) of FE
2. Function of the

PFMEA Action

PFMEA Action
Occurrence (O)

Occurrence (O)
Characteristics

Characteristics
3.Process Work process item

Priority (AP)

Priority (AP)
Detection (D)

Detection(D)
1.Process Items 2.Process Steps process step and 3. Functional of the

Severity(S)
of FC/ FM
Element Function Failure Effects (FE) to the next Current Detection Target Status (Open, Action taken

Special

Special
of FC
System, Subsystem, Station number and product process work element Failure Mode (FM) Failure Cause (FC) of the work Current Prevention Prevention Responsible Completion
Man, Machine, of System, Sub higher level element and / or End controls (DC) of FC or Detection Action completion Completed, with pointer Remarks
Part element or Name of Focus characteristic and process of the process step element control (PC) of FC Action Person Name Date
Material, system, Part element user FM date Discarded) to evidence
Name of the process element ( Quantitative value characteristic
Environment etc. or Process
is optional)

Part Element Operation Name ABC AA Man 1. In Plant AA - Under Size Man
ABC Operation No. 1 Man ----------
Machine
Method Machine Machine
Material
Environment 2. Ship To Plant
Method Method
Product DEF
DEF ----------------
Material Material
3. End User

Environment Environment

Sub System GHI Man 1. In Plant AA - Over Size Man

GHI ----------------

Machine Machine

2. Ship To Plant
System JKL Method Method
JKL ----------------

Material Material
3. End User

Environment Environment

BB Man 1. In Plant BB - Under Size Man

Man
Machine
Method Machine Machine
Material
Environment 2. Ship To Plant
Method Method

Material Material
3. End User

Environment Environment

Man 1. In Plant BB - Over Size Man

Machine Machine

2. Ship To Plant
Method Method

Material Material
3. End User

Environment Environment

Operation Name CC Man 1. In Plant CC - Under Size Man

Operation No. 2 Man Cylinder Liner
Machine Providing Sliding
Method Surface to Piston Machine Machine
Material Rings while
retaining Lubricant
2. Ship To Plant
within
Environment Method Method

Material Material
3. End User

Environment Environment

Rev.No. Rev. Date Revision Detail

NN DD.MM.YYYY Updated w.r.t. AIAG-VDA 1st. Edition
 Document Number 4QS/FM/
of 4
Failure Mode and Effects Analysis (Process FMEA) Rev. No. & Dated
Page No.
Company Name Customer Name Subject Process Responsibility PFMEAStart Date

Manufacturing Location Model Year / Program CFT/MDT/Core Team Confidential Level PFMEA Revision Date

Structure Analysis Functional Analysis Failure Analysis Risk Analysis Optimization

1. Function of

Severity(S) of FE
2. Function of the

PFMEA Action

PFMEA Action
Occurrence (O)

Occurrence (O)
Characteristics

Characteristics
3.Process Work process item

Priority (AP)

Priority (AP)
Detection (D)

Detection(D)
1.Process Items 2.Process Steps process step and 3. Functional of the

Severity(S)
of FC/ FM
Element Function Failure Effects (FE) to the next Current Detection Target Status (Open, Action taken

Special

Special
of FC
System, Subsystem, Station number and product process work element Failure Mode (FM) Failure Cause (FC) of the work Current Prevention Prevention Responsible Completion
Man, Machine, of System, Sub higher level element and / or End controls (DC) of FC or Detection Action completion Completed, with pointer Remarks
Part element or Name of Focus characteristic and process of the process step element control (PC) of FC Action Person Name Date
Material, system, Part element user FM date Discarded) to evidence
Name of the process element ( Quantitative value characteristic
Environment etc. or Process
is optional)

Prepared
Prepared By Production Engineer (M)
By Director - Operations
Signature Signature

Date Date