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JJ FMEA Sample

This document provides information on 10 operations for producing a core product. It lists potential failure modes for key product and process parameters at each operation, potential effects of failures, possible causes, current prevention and detection controls, recommended actions, and responsibility and target completion dates to address risks. The operations include loading/unloading, incoming inspection, batch weighing, mixing/kneading, extrusion, pellatising, packing, and storage. The document aims to ensure quality by identifying issues that could impact safety, integrity, specifications or consistency of the product being manufactured.

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Rahul Yadav
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as XLSX, PDF, TXT or read online on Scribd
0% found this document useful (0 votes)
122 views6 pages

JJ FMEA Sample

This document provides information on 10 operations for producing a core product. It lists potential failure modes for key product and process parameters at each operation, potential effects of failures, possible causes, current prevention and detection controls, recommended actions, and responsibility and target completion dates to address risks. The operations include loading/unloading, incoming inspection, batch weighing, mixing/kneading, extrusion, pellatising, packing, and storage. The document aims to ensure quality by identifying issues that could impact safety, integrity, specifications or consistency of the product being manufactured.

Uploaded by

Rahul Yadav
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as XLSX, PDF, TXT or read online on Scribd
You are on page 1/ 6

Page 1 of 6

SupplierSupplier Part No : Supplier Part Rev No : B Supplier Part Rev Date :


Core T Approved By :

Opn Product Process


Operation/process Machine / Equipment
No : Parameters Parameters

Integrity of Product Handling method


1 Loading Unloading ID skills

incoming inspection
issue of material
% ingredient Skill
2 batch weighing Identifications
total wt. Weighing Balance Accuracy
output rate rate of charging
3 Charging

Uniformity Mixing Time


4 Mixing/ Kneading
Batch wt./ size Mixing Speed

5 Feeding

Appearance Uniform Screw RPM


Ash Content Torque Load
Strands smooth ness Melt Pressure
6 Extrusion M.B Granules size Melt Temperature
Moisture Content Vacuum Gauge
Specific Gravity Cutting Speed
Output Rate
Bulk Density
7 Pellatising (granulation) C.P.G

classification Filter Pressure valve


Dehumidification Colour strength
8
Shade Different
Dispersion

Packing/ Pelletization/ stacking


9
Film/chip making
Storage / Loading

10
Film/chip making

Revision Details
Rev Rev Details.
No.
Page 2 of 6
Core Team : NJ, VP, RIP, SKM Model Year(s) / Program(s) : Approved By
SPECIAL CHRACTERISTICS SYMBOL SAFETY CRITICAL MAJOR

Action Results

Classification

Occurrence

Detection
Severity
Potential Cause(s) of Responsibility &

Occurrence

Detection
Process/Function Potential Failure Mode(Product Potential Effect(s) Current Process Controls Current Proces Controls Recommended

RPN

Severity
OP. No. Failure(proess parameter not Target Completion Action Taken &
Requirements parameter not achieved) of Failure (Prevention) (Detection) Action

RPN
foloowed) Date Effective Date

Integrity of Product is not maintained Not Proper Handling method.


1 Loading Unloading Not Proper skill
NOT Valid ID

% ingredient is not maintained (High/low) Poor Skills

Calibration not ok/ manual check by STM 200= install auromation


total weight not achived color variation 4- 5

10

60
2 batch weighiing 10 3 months installed

3
Wrong Identifications every 24 hour 10X4X5 control

Weighing Balance Accuracy is not


correct

Rate of charging is not


output rate is not fixed maintained

3 Charging

Uniformity is not maintained Mixing Time is not mixed

Batch wt./ size is not fixed Mixing Speed is variable

4 Mixing/ Kneading

5 Feeding

Screw RPM is variable


Appearance is not Uniform Torque Load is variable
Ash Content is not maintained
Melt Pressure is not
(high/ low) maintained
M.B
6 Extrusion Granules size is not maintained
Melt Temperature is not
Moisture Content is not uniform maintained
Vacuum Guage is not fixed
Specific Gravity is not
fixed Cutting Speed is variable
Output Rate is variable
Page 3 of 6
Core Team : NJ, VP, RIP, SKM Model Year(s) / Program(s) : Approved By
SPECIAL CHRACTERISTICS SYMBOL SAFETY CRITICAL MAJOR

Action Results

Classification

Occurrence

Detection
Severity
Potential Cause(s) of Responsibility &

Occurrence

Detection
Process/Function Potential Failure Mode(Product Potential Effect(s) Current Process Controls Current Proces Controls Recommended

RPN

Severity
OP. No. Requirements parameter not achieved) of Failure Failure(proess parameter not (Prevention) (Detection) Action Target Completion Action Taken &

RPN
foloowed) Date Effective Date

7 Cutting Bulk Density C.P.G

Filter Pressure valve

Film/ Chip Making Color strength is not maintained

Shade Different is not maintained

Dispersion is not maintained

9 Packing

10 Storage / Loading
Page 4 of 6

Core Team : NJ, VP, RIP, SKM Model Year(s) / Program(s) : Approved By
SPECIAL CHRACTERISTICS SYMBOL SAFETY CRITICAL MAJOR

Action Results

Classification

Occurrence

Detection
Severity
Potential Cause(s) of Responsibility &

Occurrence

Detection
Process/Function Potential Failure Mode(Product Potential Effect(s) Current Process Controls Current Proces Controls Recommended

RPN

Severity
OP. No. Requirements parameter not achieved) of Failure Failure(proess parameter not (Prevention) (Detection) Action Target Completion Action Taken &

RPN
foloowed) Date Effective Date

Revision Details.

Rev. No. Rev. Date Revision Details


Page 5 of 6

CONTROL PLAN Rev. No : 1


Prototype Pre launch Production Key Contact Person : Contact No : 1 of 2
Customer : Customer Part No : Rev Date : Rev. No :
Supplier : Supplier Part No : Rev Date : Rev. No :
Core Team : Plant / Section :
Characteristics Symbol : Safety Critical Major
Characteristics Methods
Process Name / Machine, special spec
Pro-cess
Operation Device, Jig, Char. / nominal Evaluation Sample Control Reaction Plan
No. Responsi-
description Tools for mfg. No. Product Process class value Product / Process/ Tolerance measurement method &
bility
Technique Error Proofing
Size Freequency

1) Integrity of Product
2) ID

Loading
1
Unloading
1) Handling method
2) skills

additive log
% ingredient JTM keep aside and inform to senior
book
every batch
weighing scale 5 kg lc
total weisght 3.5 +-1 gm 1 gm ws 55
*

2 batch weighing
Identifications

Weighing Balance Accuracy

output rate
3 Charging

rate of charging

1) Uniformity
2) Batch wt./ size

Mixing/
4 Kneading
1) Mixing Time
2) Mixing Speed

5 Feeding

Appearance Uniform
Ash Content 200% day
Page 6 of 6

CONTROL PLAN Rev. No : 1


Prototype Pre launch Production Key Contact Person : Contact No : 1 of 2
Customer : Customer Part No : Rev Date : Rev. No :
Supplier : Supplier Part No : Rev Date : Rev. No :
Core Team : Plant / Section :
Characteristics Symbol : Safety Critical Major
Characteristics Methods
Process Name / Machine, special spec
Pro-cess
Operation Device, Jig, Char. / nominal Evaluation Sample Control Reaction Plan
No. Responsi-
description Tools for mfg. No. Product Process class value Product / Process/ Tolerance measurement method &
bility
Technique Error Proofing
Size Freequency
Strands
M.B Granules size
Moisture Content
Specific Gravity
6 Extrusion Screw RPM
Torque Load
Melt Pressure
Melt Temperature
Vacuum Gauge
Cutting Speed
Output Rate
Bulk Density
C.P.G
7 Cutting

Filter Pressure valve


Film/chip Colour strength
making Shade Different
8
Dispersion

9 Packing

Storage /
10 Loading

Rev. no. Rev. Date Description of Changes

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