Doc. No.

PDC-EPD-F03

PROCESS FAILURE MODE AND EFFECTS ANALYSIS Rev. No. (Date) 00 (01/12/2017)

Issue No. (Date) 01 (01/12/2017)

PFMEA Number 894172529 FMEA-MCD-01 Key Contact / Phone Name / Works / Dept Team Member Department
Rev. No. (Date) 00(01/01/14) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) 1/1/2014 Mr. R.R. Sharma Head Quality
Part Number 894172529 Mr. Pradeep Garg G.M. Operation
Process Responsibility: Core Team
Part Name / Description GMI Flywheel Mr. Himanshu Duniwal Manager QMS
Material Grade FC 23 Key Date : 1-Jan-14 Mr. R S Shekhawat Manager - EPD

Current Process Controls Recom Respo Action Results

mende nsibilit
Potential Failure
Process Function / Requirements Potential Effect(s) of Failure B. No S C Potential Cause(s) / Mechanism(s) of Failure O D RPN d y&
Mode
Action Target
Prevention Detection s Date Actions Taken S O D RPN

Rejection Increases,
More 6 2 6 72
Assembly Problems Incorrect Programing,Incorrect Set up of
Set up Approval, In Process Sampling Test
Inner Diameter Ø 50.8 / 51.2 mm 1 Fixture,loose Mounting/Clamping,Faulty Tool Travel
Inspection Every lot
Rework Increases, , Tool Wear
Less 5 2 6 60
Assembly Problems

Rejection Increases,
More 8 2 2 32
Assembly Problems Incorrect Programing,Incorrect Set up of Set up Approval,In Process
Ø 95.000 / 95.040 Sampling Test
Inner Diameter
mm
2 ▼ Fixture,loose Mounting/Clamping,Faulty Tool Inspection,Operator
Every lot
Rework Increases, Travel , Tool Wear Monitoring,SPC
Less 7 2 2 28
Assembly Problems

Rework Increases,
More 6 2 5 60
Assembly Problems Incorrect Programing,Incorrect Set up of
Ø 110.7 / 111.3 Sampling Test
Outer Diameter 3 Fixture,loose Mounting/Clamping,Faulty Tool Travel Set up Approval
mm Every lot
Rejection Increases, , Tool Wear
Less 5 2 5 50
Assembly Problems

Rejection Increases,
More 6 2 6 72
Assembly Problems Incorrect Programing,Incorrect Set up of
Ø 229.00 / 232.00 Sampling Test
Inner Diameter 4 Fixture,loose Mounting/Clamping,Faulty Tool Travel Set up Approval
mm Every lot
Rework Increases, , Tool Wear
Less 5 2 6 60
Assembly Problems

Rework Increases,
More 8 2 2 32
Assembly Problems Incorrect Programing,Incorrect Set up of Set up Approval,In Process
Ø 271.30 / 271.40 Sampling Test
Outer Diameter 6 ▼ Fixture,loose Mounting/Clamping,Faulty Tool Inspection,Operator
mm Every lot
Rejection Increases, Travel , Tool Wear Monitoring,SPC
Less 7 2 2 28
Assembly Problems

Rework Increases,
More 6 2 5 60
Assembly Problems Incorrect Programing,Incorrect Set up of
Ø 275.5 / 276.5 Sampling Test
Outer Diameter 7 Fixture,loose Mounting/Clamping,Faulty Tool Travel Set up Approval
mm Every lot
Rejection Increases, , Tool Wear
Less 5 2 5 50
Assembly Problems

Rework Increases,
More 6 2 5
Assembly Problems Incorrect Programing,Incorrect Set up of
Ø 296.7 / 297.3 Set up Approval,In Process Sampling Test
Outer Diameter 8 Fixture,loose Mounting/Clamping,Faulty Tool Travel 60
mm Inspection,Operator Monitoring, Every lot
Rejection Increases, , Tool Wear
Less 5 2 5
Assembly Problems

Rejection Increases,
Less 6 2 6 72
Assembly Problems Incorrect Programing,Incorrect Set up of
Sampling Test
Depth 16.50 / 18.00 mm 9 Fixture,loose Mounting/Clamping,Faulty Tool Travel Set up Approval
Every lot
Rework Increases, , Tool Wear
More 5 2 6 60
Assembly Problems

Incorrect Programing,Incorrect Set up of

Radius Rejection Increases, Set up Approval & Sampling Test
R10 More 12 4 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 7 56
R0.6/0.8 Assembly Problems Program Controlled Every lot
, Tool Wear

1 of 12
 Doc. No. PDC-EPD-F03

PROCESS FAILURE MODE AND EFFECTS ANALYSIS Rev. No. (Date) 00 (01/12/2017)

Issue No. (Date) 01 (01/12/2017)

PFMEA Number 894172529 FMEA-MCD-01 Key Contact / Phone Name / Works / Dept Team Member Department
Rev. No. (Date) 00(01/01/14) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) 1/1/2014 Mr. R.R. Sharma Head Quality
Part Number 894172529 Mr. Pradeep Garg G.M. Operation
Process Responsibility: Core Team
Part Name / Description GMI Flywheel Mr. Himanshu Duniwal Manager QMS
Material Grade FC 23 Key Date : 1-Jan-14 Mr. R S Shekhawat Manager - EPD

Current Process Controls Recom Respo Action Results

mende nsibilit
Potential Failure
Process Function / Requirements Potential Effect(s) of Failure B. No S C Potential Cause(s) / Mechanism(s) of Failure O D RPN d y&
Mode
Action Target
Prevention Detection s Date Actions Taken S O D RPN

Rework Increases,
Less 6 Incorrect Programing,Incorrect Set up of 2 7 84
Assembly Problems Set up Approval , Sampling Test
Chamfer 13 Fixture,loose Mounting/Clamping,Faulty Tool Travel
1.5 X 45° Rejection Increases, Program Controlled Every lot
More 5 , Tool Wear 2 7 70
Assembly Problems

Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval & Sampling Test
Radius R0.8 More 14 4 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 7 56
Assembly Problems Program Controlled Every lot
, Tool Wear

Incorrect Programing,Incorrect Set up of

Rejection Increases, Sampling Test
Angle 30° More / Less 15 7 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 Pattern Controlled 4 56
Assembly Problems Every lot
, Tool Wear

Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval & Sampling Test
Radius R3.0 More 16 4 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 7 56
Assembly Problems Program Controlled Every lot
, Tool Wear

Rework Increases,
Less 6 Incorrect Programing,Incorrect Set up of 2 7 84
Assembly Problems Set up Approval , Sampling Test
Chamfer 17 Fixture,loose Mounting/Clamping,Faulty Tool Travel
0.5 X 45° Rejection Increases, Program Controlled Every lot
More 5 , Tool Wear 2 7 70
Assembly Problems

Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval , Sampling Test
Surface Finish 25μRa More 18 6 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 7 84
Assembly Problems Program Controlled Every lot
, Tool Wear

Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval , Sampling Test
Surface Finish 6.3μRa More 19 6 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 7 84
Assembly Problems Program Controlled Every lot
, Tool Wear

Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval , Sampling Test
Surface Finish 25μRa More 20 6 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 7 84
Assembly Problems Program Controlled Every lot
, Tool Wear

Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval , Sampling Test
Surface Finish 6.3μRa More 21 6 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 7 84
Assembly Problems Program Controlled Every lot
, Tool Wear

Rework Increases,
Less 6 Incorrect Programing,Incorrect Set up of 2 7 84
Assembly Problems Set up Approval , Sampling Test
Chamfer 1.0 X 45° 22 Fixture,loose Mounting/Clamping,Faulty Tool Travel
Rejection Increases, Program Controlled Every lot
More 5 , Tool Wear 2 7 70
Assembly Problems

Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval & Sampling Test
Radius R0.2/0.5 More 23 4 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 7 56
Assembly Problems Program Controlled Every lot
, Tool Wear

2 of 12
 Doc. No. PDC-EPD-F03

PROCESS FAILURE MODE AND EFFECTS ANALYSIS Rev. No. (Date) 00 (01/12/2017)

Issue No. (Date) 01 (01/12/2017)

PFMEA Number 894172529 FMEA-MCD-01 Key Contact / Phone Name / Works / Dept Team Member Department
Rev. No. (Date) 00(01/01/14) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) 1/1/2014 Mr. R.R. Sharma Head Quality
Part Number 894172529 Mr. Pradeep Garg G.M. Operation
Process Responsibility: Core Team
Part Name / Description GMI Flywheel Mr. Himanshu Duniwal Manager QMS
Material Grade FC 23 Key Date : 1-Jan-14 Mr. R S Shekhawat Manager - EPD

Current Process Controls Recom Respo Action Results

mende nsibilit
Potential Failure
Process Function / Requirements Potential Effect(s) of Failure B. No S C Potential Cause(s) / Mechanism(s) of Failure O D RPN d y&
Mode
Action Target
Prevention Detection s Date Actions Taken S O D RPN

Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval , Sampling Test
Surface Finish 6.3μRa More 24 6 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 7 84
Assembly Problems Program Controlled Every lot
, Tool Wear

Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval , Sampling Test
Surface Finish 25μRa More 25 6 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 7 84
Assembly Problems Program Controlled Every lot
, Tool Wear

Rejection Increases,
Less 6 2 4 48
Assembly Problems Incorrect Programing,Incorrect Set up of
Sampling Test
Depth 4.7 / 6.2 mm 26 Fixture,loose Mounting/Clamping,Faulty Tool Travel Set up Approval
Every lot
Rework Increases, , Tool Wear
More 5 2 4 40
Assembly Problems

Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval , Sampling Test
Surface Finish 6.3μRa More 27 6 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 7 84
Assembly Problems Program Controlled Every lot
, Tool Wear

Rejection Increases,
Less 6 2 4 48
Assembly Problems Incorrect Programing,Incorrect Set up of
Set up Approval,In Process Sampling Test
Depth 12.5 / 12.7 mm 28 Fixture,loose Mounting/Clamping,Faulty Tool Travel
Inspection Every lot
Rework Increases, , Tool Wear
More 5 2 4 40
Assembly Problems

Rejection Increases,
Less 6 2 5 60
Assembly Problems Incorrect Programing,Incorrect Set up of
Set up Approval,In Process Sampling Test
Chamfer Depth 1.4 / 1.6 mm 29 Fixture,loose Mounting/Clamping,Faulty Tool Travel
Inspection Every lot
Rework Increases, , Tool Wear
More 5 2 5 50
Assembly Problems

Rejection Increases,
Less 6 2 4 48
Assembly Problems Incorrect Programing,Incorrect Set up of
Set up Approval,In Process Sampling Test
Depth 6.80 / 7.20 mm 30 Fixture,loose Mounting/Clamping,Faulty Tool Travel
Inspection Every lot
Rework Increases, , Tool Wear
More 5 2 4 40
Assembly Problems

Rejection Increases,
Less 6 2 4 48
Assembly Problems Incorrect Programing,Incorrect Set up of
Set up Approval, In Process Sampling Test
Depth 61.9 / 62.1 mm 31 Fixture,loose Mounting/Clamping,Faulty Tool Travel
Inspection Every lot
Rework Increases, , Tool Wear
More 5 2 4 40
Assembly Problems

3 of 12
 Doc. No. PDC-EPD-F03

PROCESS FAILURE MODE AND EFFECTS ANALYSIS Rev. No. (Date) 00 (01/12/2017)

Issue No. (Date) 01 (01/12/2017)

PFMEA Number 894172529 FMEA-MCD-01 Key Contact / Phone Name / Works / Dept Team Member Department
Rev. No. (Date) 00(01/01/14) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) 1/1/2014 Mr. R.R. Sharma Head Quality
Part Number 894172529 Mr. Pradeep Garg G.M. Operation
Process Responsibility: Core Team
Part Name / Description GMI Flywheel Mr. Himanshu Duniwal Manager QMS
Material Grade FC 23 Key Date : 1-Jan-14 Mr. R S Shekhawat Manager - EPD

Current Process Controls Recom Respo Action Results

mende nsibilit
Potential Failure
Process Function / Requirements Potential Effect(s) of Failure B. No S C Potential Cause(s) / Mechanism(s) of Failure O D RPN d y&
Mode
Action Target
Prevention Detection s Date Actions Taken S O D RPN

Rejection Increases,
Less 6 2 4 48
Assembly Problems Incorrect Programing,Incorrect Set up of
Set up Approval, In Process Sampling Test
Depth 41.9 / 42.1 mm 32 Fixture,loose Mounting/Clamping,Faulty Tool Travel
Inspection Every lot
Rework Increases, , Tool Wear
More 5 2 4 40
Assembly Problems

Rejection Increases,
Less 6 2 4 48
Assembly Problems Incorrect Programing,Incorrect Set up of
Sampling Test
Depth 7.8 / 8.2 mm 33 Fixture,loose Mounting/Clamping,Faulty Tool Travel Set up Approval
Every lot
Rework Increases, , Tool Wear
More 5 2 4 40
Assembly Problems

Rejection Increases,
Less 6 2 4 48
Assembly Problems Incorrect Programing,Incorrect Set up of
Sampling Test
Depth 33.70 / 34.30 mm 34 Fixture,loose Mounting/Clamping,Faulty Tool Travel Set up Approval
Every lot
Rework Increases, , Tool Wear
More 5 2 4 40
Assembly Problems

Rejection Increases,
Less 6 2 4 48
Assembly Problems Incorrect Programing,Incorrect Set up of
Sampling Test
Depth 17.3 / 17.8 mm 35 Fixture,loose Mounting/Clamping,Faulty Tool Travel Set up Approval
Every lot
Rework Increases, , Tool Wear
More 5 2 4 40
Assembly Problems

Rejection Increases,
Less 6 2 4 48
Assembly Problems Incorrect Programing,Incorrect Set up of
Set up Approval,In Process Sampling Test
Width 15.3 / 15.7 mm 36 Fixture,loose Mounting/Clamping,Faulty Tool Travel
Inspection Every lot
Rework Increases, , Tool Wear
More 5 2 4 40
Assembly Problems

Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval , Sampling Test
Surface Finish 6.3μRa More 37 5 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 7 70
Assembly Problems Program Controlled Every lot
, Tool Wear

Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval , Sampling Test
Surface Finish 6.3μRa More 38 5 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 7 70
Assembly Problems Program Controlled Every lot
, Tool Wear

Incorrect Programing,Incorrect Set up of

Rejection Increases, Sampling Test
Groove Depth 0.0 -1.0 mm More 39 5 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 Program Controlled 7 70
Assembly Problems Every lot
, Tool Wear

0.07 TIR MAX. Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval, In Process Sampling Test
Parallesim with Ref. 'C' on More
Assembly Problems
40 8 ▼ Fixture,loose Mounting/Clamping,Faulty Tool 2
Inspection(On Part) Every lot
2 32
Ø 225 mm Travel , Tool Wear

Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval , Sampling Test
Surface Finish 25μRa More 41 6 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 7 84
Assembly Problems Program Controlled Every lot
, Tool Wear

4 of 12
 Doc. No. PDC-EPD-F03

PROCESS FAILURE MODE AND EFFECTS ANALYSIS Rev. No. (Date) 00 (01/12/2017)

Issue No. (Date) 01 (01/12/2017)

PFMEA Number 894172529 FMEA-MCD-01 Key Contact / Phone Name / Works / Dept Team Member Department
Rev. No. (Date) 00(01/01/14) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) 1/1/2014 Mr. R.R. Sharma Head Quality
Part Number 894172529 Mr. Pradeep Garg G.M. Operation
Process Responsibility: Core Team
Part Name / Description GMI Flywheel Mr. Himanshu Duniwal Manager QMS
Material Grade FC 23 Key Date : 1-Jan-14 Mr. R S Shekhawat Manager - EPD

Current Process Controls Recom Respo Action Results

mende nsibilit
Potential Failure
Process Function / Requirements Potential Effect(s) of Failure B. No S C Potential Cause(s) / Mechanism(s) of Failure O D RPN d y&
Mode
Action Target
Prevention Detection s Date Actions Taken S O D RPN

Rejection Increases,
Less 6 2 4 48
Assembly Problems Incorrect Programing,Incorrect Set up of
Sampling Test
Ream Depth 9.80 / 10.20 mm 42 Fixture,loose Mounting/Clamping,Faulty Tool Travel Set up Approval
Every lot
Rework Increases, , Tool Wear
More 5 2 4 40
Assembly Problems

Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval , Sampling Test
Surface Finish 6.3μRa More 43 6 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 7 84
Assembly Problems Program Controlled Every lot
, Tool Wear

Rejection Increases,
Less 6 2 4 48
Assembly Problems Incorrect Programing,Incorrect Set up of
Sampling Test
Drill Depth 13.80 /14.20 mm 44 Fixture,loose Mounting/Clamping,Faulty Tool Travel Set up Approval
Every lot
Rework Increases, , Tool Wear
More 5 2 4 40
Assembly Problems

Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval , Sampling Test
Surface Finish 6.3μRa More 45 6 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 7 84
Assembly Problems Program Controlled Every lot
, Tool Wear

Rejection Increases,
More 6 2 6 72
Assembly Problems Incorrect Programing,Incorrect Set up of
Ø 117.7 / 118.3 Set up Approval , Sampling Test
Inner Diameter 46 Fixture,loose Mounting/Clamping,Faulty Tool Travel
mm Program Controlled Every lot
Rework Increases, , Tool Wear
Less 5 2 6 60
Assembly Problems

Rejection Increases,
More 6 2 6 72
Assembly Problems Incorrect Programing,Incorrect Set up of
Ø 135.5 / 136.5 Set up Approval , Sampling Test
Inner Diameter 47 Fixture,loose Mounting/Clamping,Faulty Tool Travel
mm Program Controlled Every lot
Rework Increases, , Tool Wear
Less 5 2 6 60
Assembly Problems

Rejection Increases,
More 6 2 6 72
Assembly Problems Incorrect Programing,Incorrect Set up of
Ø 149.0 / 151.0 Set up Approval , Sampling Test
Inner Diameter 48 Fixture,loose Mounting/Clamping,Faulty Tool Travel
mm Program Controlled Every lot
Rework Increases, , Tool Wear
Less 5 2 6 60
Assembly Problems

Rejection Increases,
More 6 2 7 84
Assembly Problems Incorrect Programing,Incorrect Set up of
Groove Inner Ø 229.5 / 230.5 Sampling Test
49 Fixture,loose Mounting/Clamping,Faulty Tool Travel Program Controlled
Diameter mm Every lot
Rework Increases, , Tool Wear
Less 5 2 6 60
Assembly Problems

Rejection Increases,
More 6 2 6 72
Assembly Problems Incorrect Programing,Incorrect Set up of
Ø 234.5 / 235.5 Set up Approval,In Process Sampling Test
Inner Diameter 50 Fixture,loose Mounting/Clamping,Faulty Tool Travel
mm Inspection,Operator Monitoring, Every lot
Rework Increases, , Tool Wear
Less 5 2 6 60
Assembly Problems

Rework Increases,
More 6 2 5 60
Assembly Problems Incorrect Programing,Incorrect Set up of
Ø 290.5 / 291.5 Sampling Test
Outer Diameter 51 Fixture,loose Mounting/Clamping,Faulty Tool Travel Set up Approval
mm Every lot
Rejection Increases, , Tool Wear
Less 5 2 5 50
Assembly Problems

5 of 12
 Doc. No. PDC-EPD-F03

PROCESS FAILURE MODE AND EFFECTS ANALYSIS Rev. No. (Date) 00 (01/12/2017)

Issue No. (Date) 01 (01/12/2017)

PFMEA Number 894172529 FMEA-MCD-01 Key Contact / Phone Name / Works / Dept Team Member Department
Rev. No. (Date) 00(01/01/14) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) 1/1/2014 Mr. R.R. Sharma Head Quality
Part Number 894172529 Mr. Pradeep Garg G.M. Operation
Process Responsibility: Core Team
Part Name / Description GMI Flywheel Mr. Himanshu Duniwal Manager QMS
Material Grade FC 23 Key Date : 1-Jan-14 Mr. R S Shekhawat Manager - EPD

Current Process Controls Recom Respo Action Results

mende nsibilit
Potential Failure
Process Function / Requirements Potential Effect(s) of Failure B. No S C Potential Cause(s) / Mechanism(s) of Failure O D RPN d y&
Mode
Action Target
Prevention Detection s Date Actions Taken S O D RPN

Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval & Sampling Test
Radius R3.0 More 53 4 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 7 56
Assembly Problems Program Controlled Every lot
, Tool Wear

Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval & Sampling Test
Radius R3.0 More 54 4 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 7 56
Assembly Problems Program Controlled Every lot
, Tool Wear

Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval , Sampling Test
Surface Finish 25μRa More 55 6 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 7 84
Assembly Problems Program Controlled Every lot
, Tool Wear

Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval , Sampling Test
Surface Finish 25μRa More 56 6 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 7 84
Assembly Problems Program Controlled Every lot
, Tool Wear

Incorrect Programing,Incorrect Set up of

Rejection Increases, Sampling Test
Angle 2° More / Less 57 4 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 Program Controlled 7 56
Assembly Problems Every lot
, Tool Wear

Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval & Sampling Test
Radius R3.0 More 61 4 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 7 56
Assembly Problems Program Controlled Every lot
, Tool Wear

Set up Approval /
Incorrect Programing,Incorrect Set up of
Rejection Increases, CMM Report Sampling Test
Dimension 62.7 / 62.8 mm More / Less 67 8 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 4 64
Assembly Problems & Every lot
, Tool Wear
Program Controlled

Set up Approval /
Incorrect Programing,Incorrect Set up of
108.64 / 108.74 Rejection Increases, CMM Report Sampling Test
Dimension More / Less 68 8 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 4 64
mm Assembly Problems & Every lot
, Tool Wear
Program Controlled

Set up Approval /
Incorrect Programing,Incorrect Set up of
108.64 / 108.74 Rejection Increases, CMM Report Sampling Test
Dimension More / Less 69 8 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 4 64
mm Assembly Problems & Every lot
, Tool Wear
Program Controlled

Set up Approval /
Incorrect Programing,Incorrect Set up of
Rejection Increases, CMM Report Sampling Test
Dimension 134.7 mm More / Less 70 8 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 4 64
Assembly Problems & Every lot
, Tool Wear
Program Controlled

Set up Approval /
Incorrect Programing,Incorrect Set up of
Rejection Increases, CMM Report Sampling Test
Dimension 62.7 / 62.8 mm More / Less 71 8 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 4 64
Assembly Problems & Every lot
, Tool Wear
Program Controlled
6 of 12
 Doc. No. PDC-EPD-F03

PROCESS FAILURE MODE AND EFFECTS ANALYSIS Rev. No. (Date) 00 (01/12/2017)

Issue No. (Date) 01 (01/12/2017)

PFMEA Number 894172529 FMEA-MCD-01 Key Contact / Phone Name / Works / Dept Team Member Department
Rev. No. (Date) 00(01/01/14) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) 1/1/2014 Mr. R.R. Sharma Head Quality
Part Number 894172529 Mr. Pradeep Garg G.M. Operation
Process Responsibility: Core Team
Part Name / Description GMI Flywheel Mr. Himanshu Duniwal Manager QMS
Material Grade FC 23 Key Date : 1-Jan-14 Mr. R S Shekhawat Manager - EPD

Current Process Controls Recom Respo Action Results

mende nsibilit
Potential Failure
Process Function / Requirements Potential Effect(s) of Failure B. No S C Potential Cause(s) / Mechanism(s) of Failure O D RPN d y&
Mode
Action Target
Set Prevention
up Approval / Detection s Date Actions Taken S O D RPN
Incorrect Programing,Incorrect Set up of
Rejection Increases, CMM Report Sampling Test
Dimension 62.7 / 62.8 mm More / Less 71 8 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 4 64
Assembly Problems & Every lot
, Tool Wear
Program Controlled

Set up Approval /
Incorrect Programing,Incorrect Set up of
125.45 / 125.55 Rejection Increases, CMM Report Sampling Test
Dimension More / Less 72 8 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 4 64
mm Assembly Problems & Every lot
, Tool Wear
Program Controlled

2
Incorrect Programing,Incorrect Set up of
Rejection Increases, Set up Approval,Operator Sampling Test
PCD Ø 74.00 mm More/Less 73 8 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 32
Assembly Problems Monitoring,In-Process Inspection Every lot
, Tool Wear
2

Incorrect Programing,Incorrect Set up of

Rejection Increases, Sampling Test
Radius R120.0 mm More / Less 74 4 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 Program Controlled 7 56
Assembly Problems Every lot
, Tool Wear

2
Incorrect Programing,Incorrect Set up of
Rejection Increases, Set up Approval,Operator Sampling Test
PCD Ø 251.00 mm More/Less 75 8 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 32
Assembly Problems Monitoring,In-Process Inspection Every lot
, Tool Wear
2

Set up Approval /
Incorrect Programing,Incorrect Set up of
Rejection Increases, CMM Report Sampling Test
Angle 13.50 ° More / Less
Assembly Problems
0 7 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2
& Every lot
8 112
, Tool Wear
Program Controlled

Set up Approval /
Incorrect Programing,Incorrect Set up of
Rejection Increases, CMM Report Sampling Test
0 73 ͦ30'± 10' More / Less 77 7 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 8 112
Assembly Problems & Every lot
, Tool Wear
Program Controlled

Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval,Operator Sampling Test
0 120 ͦ More / Less 78 7 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 8 112
Assembly Problems Monitoring,In-Process Inspection Every lot
, Tool Wear

Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval,Operator Sampling Test
0 Equally Spaced More / Less 79 7 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 8 112
Assembly Problems Monitoring,In-Process Inspection Every lot
, Tool Wear

Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval,Operator Sampling Test
Drill Dia Ø 13.5 mm More / Less 8 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 3 48
Assembly Problems Monitoring,In-Process Inspection Every lot
, Tool Wear

80

Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval,Operator Sampling Test
0 Equally Spaced More / Less 8 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 3 48
Assembly Problems Monitoring,In-Process Inspection Every lot
, Tool Wear
7 of 12
 Doc. No. PDC-EPD-F03

PROCESS FAILURE MODE AND EFFECTS ANALYSIS Rev. No. (Date) 00 (01/12/2017)

Issue No. (Date) 01 (01/12/2017)

PFMEA Number 894172529 FMEA-MCD-01 Key Contact / Phone Name / Works / Dept Team Member Department
Rev. No. (Date) 00(01/01/14) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) 1/1/2014 Mr. R.R. Sharma Head Quality
Part Number 894172529 Mr. Pradeep Garg G.M. Operation
Process Responsibility: Core Team
Part Name / Description GMI Flywheel Mr. Himanshu Duniwal Manager QMS
Material Grade FC 23 Key Date : 1-Jan-14 Mr. R S Shekhawat Manager - EPD

Current Process Controls Recom Respo Action Results

mende nsibilit
Potential Failure
Process Function / Requirements Potential Effect(s) of Failure B.80
No S C Potential Cause(s) / Mechanism(s) of Failure O D RPN d y&
Mode
Action Target
Prevention Detection s Date Actions Taken S O D RPN
Incorrect Programing,Incorrect Set up of
Rejection Increases, Set up Approval,Operator Sampling Test
0 Equally Spaced More / Less 8 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 3 48
Assembly Problems Monitoring,In-Process Inspection Every lot
, Tool Wear

Rejection Increases,
More 8 3
Assembly Problems Incorrect Programing,Incorrect Set up of
Set up Approval,Operator Sampling Test
Tap M8 X 1.25 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 48
Monitoring,In-Process Inspection Every lot
, Tool Wear
Less Rework Increases 7 3

Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval,Operator Sampling Test
6 Tapped Holes Equally Spaced More / Less 81 8 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 3 48
Assembly Problems Monitoring,In-Process Inspection Every lot
, Tool Wear

Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval,Operator Sampling Test
0 16.00 mm More / Less 8 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 3 48
Assembly Problems Monitoring,In-Process Inspection Every lot
, Tool Wear

Rejection Increases,
More 8 2 2 32
Assembly Problems Incorrect Programing,Incorrect Set up of
Ø 5.974 / 5.988 Set up Approval , Sampling Test
0 82 Fixture,loose Mounting/Clamping,Faulty Tool Travel
mm Program Controlled Every lot
Rework Increases, , Tool Wear
Less 7 2 2 28
Assembly Problems

Rejection Increases,
More 6 2 8 96
Assembly Problems Incorrect Programing,Incorrect Set up of
Sampling Test
Width 1.9/ 2.1 85 Fixture,loose Mounting/Clamping,Faulty Tool Travel Program Controlled
Every lot
Rework Increases, , Tool Wear
Less 5 2 8 80
Assembly Problems

Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval & Sampling Test
Radius R18.0 mm More / Less 87 6 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 4 48
Assembly Problems Program Controlled Every lot
, Tool Wear

Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval & Sampling Test
Dimension 45.00 mm More / Less 88 8 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 4 64
Assembly Problems Program Controlled Every lot
, Tool Wear

Incorrect Programing,Incorrect Set up of

Rejection Increases, Set up Approval & Sampling Test
Dimension 20.00 mm More / Less 89 8 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 4 64
Assembly Problems Program Controlled Every lot
, Tool Wear

Incorrect Programing,Incorrect Set up of

Rejection Increases, Sampling Test
Angle 15° More / Less
Assembly Problems
90 7 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 Pattern Controlled
Every lot
4 56
, Tool Wear

Rejection Increases,
Less 6 2 4 48
Assembly Problems Incorrect Programing,Incorrect Set up of
Sampling Test
Depth 7.9 / 8.1 mm 91 Fixture,loose Mounting/Clamping,Faulty Tool Travel Set up Approval
Every lot
, Tool Wear
8 of 12
 Doc. No. PDC-EPD-F03

PROCESS FAILURE MODE AND EFFECTS ANALYSIS Rev. No. (Date) 00 (01/12/2017)

Issue No. (Date) 01 (01/12/2017)

PFMEA Number 894172529 FMEA-MCD-01 Key Contact / Phone Name / Works / Dept Team Member Department
Rev. No. (Date) 00(01/01/14) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) 1/1/2014 Mr. R.R. Sharma Head Quality
Part Number 894172529 Mr. Pradeep Garg G.M. Operation
Process Responsibility: Core Team
Part Name / Description GMI Flywheel Mr. Himanshu Duniwal Manager QMS
Material Grade FC 23 Key Date : 1-Jan-14 Mr. R S Shekhawat Manager - EPD

Current Process Controls Recom Respo Action Results

mende nsibilit
Potential Failure
Process Function / Requirements Potential Effect(s) of Failure B. No S C Potential Cause(s) / Mechanism(s) of Failure O D RPN d y&
Mode
Action Target
Prevention Detection s Date Actions Taken S O D RPN
Incorrect Programing,Incorrect Set up of
Sampling Test
Depth 7.9 / 8.1 mm 91 Fixture,loose Mounting/Clamping,Faulty Tool Travel Set up Approval
Every lot
Rework Increases, , Tool Wear
More 5 2 4 40
Assembly Problems

Rejection Increases,
Less 6 2 4 48
Assembly Problems Incorrect Programing,Incorrect Set up of
Set up Approval,Operator Sampling Test
Depth 17.80/18.20 mm 92 Fixture,loose Mounting/Clamping,Faulty Tool Travel
Monitoring,In-Process Inspection Every lot
Rework Increases, , Tool Wear
More 5 2 4 40
Assembly Problems

Incorrect Programing,Incorrect Set up of

Drill Dia Sampling Test
More Rejection Increases 92 4 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 Set up Approval 4 32
ɸ12.70 Max Every lot
, Tool Wear

Incorrect Programing,Incorrect Set up of

Drill Depth Sampling Test
More Rejection Increases 4 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 Set up Approval 4 32
22.00 Max. Every lot
, Tool Wear

Incorrect Programing,Incorrect Set up of

Wall Thickness Sampling Test
Less Rejection Increases 4 Fixture,loose Mounting/Clamping,Faulty Tool Travel 2 Set up Approval 4 32
7.30 Every lot
, Tool Wear

Rejection Increase, Incorrect Set up of Fixture,loose Sampling Test

Ring Fitment Loose Fit NA 8 2 Process Controlled 2 32
Assembly Problems Mounting/Clamping,Low Pressure,Less Heating Every lot

Packing Standard & Supervisor Sampling Test

Packing Quantity Per Box Less or More Supply NA 8 Operator Negligence 2 2 32
Monitoring Every lot

Remarks : Reviewed on 03/05/2016.

9 of 12
 Hindustan Malleable Casting Works POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)
EICHER TRACTORS (A Unit of Tafe Motors and
Part Name FLY WHEEL CASING Customer PFMEA No. HMCW/TMTL-01 Rev. No. 0
Tractors Limited)
Part No. 9701 063 1 Key Dates Date 22/05/08 Date 22/05/08

Core Team Vishnu Agarwal, Ankur Agarwal, Jagat Singh

RES. &
S. COMPONENT POTENTIAL FAILURE RECOM. ACTION

RPN

RPN
S C FAILURE EFFECTS FAILURE CAUSES O FAILURE PREVENTION FAILURE DETECTION D TARGET S O D
No. OR PROCESS FUNCTION MODES ACTION TAKEN
DATE

Visual Inspection of
Heat Codes Missing 6 Casting Rework & Punching Operator Negligence 4 Sampling Inspection 4 96
Patterns

Mould Mould Improper Sand Preparation

3 Low 6 Extra Material 4 Inprocess Inspection Sampling Inspection 4 96
Making Hardness & Ramming

Broken Pattern, Improper Inspection of Patterns,

Broken
Appearance 6 Defective Casting Box Setting, Improper 4 Proper Setting of Box & Sampling Inspection 4 96
Cavity
Ramming Proper Ramming

High 7 Lost in Properties Improper Charge Mixing 3 CE Test Sampling Test 4 84

CE

Low 7 Lost in Properties Improper Charge Mixing 3 CE Test Sampling Test 4 84

High 7 Lost in Properties Operator's Negligence 4 100 % Monitoring Sampling Test 4 112
Pouring
Temperature
Low 7 Lost in Properties Operator's Negligence 4 100 % Monitoring Sampling Test 4 112

Melting & Microstructu

4 Not OK 7 Casting Rejection Improper Composition 4 Inprocess Inspection Sampling Test 4 112
Pouring re Test

Low
7 Casting Rejection Improper Composition 4 Inprocess Inspection Sampling Test 4 112
Hardness
Hardness
Test
High
7 Casting Rejection Improper Composition 4 Inprocess Inspection Sampling Test 4 112
Hardness

High
7 Casting Rejection Improper Composition 4 Inprocess Inspection 4508325 4 ###
Strength
Tensile
Strength
4508404 7 4507524 4508365 4 Inprocess Inspection 4508325 4 ###

O = Failure occurrence probability D = Failure detection probability Risk Priority Number RPN = S x O x D
To be filled if RPN>150 10 of 12
 Hindustan Malleable Casting Works POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)
EICHER TRACTORS (A Unit of Tafe Motors and
Part Name FLY WHEEL CASING Customer PFMEA No. HMCW/TMTL-01 Rev. No. 0
Tractors Limited)
Part No. 9701 063 1 Key Dates Date 22/05/08 Date 22/05/08

Core Team Vishnu Agarwal, Ankur Agarwal, Jagat Singh

RES. &
S. COMPONENT POTENTIAL FAILURE RECOM. ACTION

RPN

RPN
S C FAILURE EFFECTS FAILURE CAUSES O FAILURE PREVENTION FAILURE DETECTION D TARGET S O D
No. OR PROCESS FUNCTION MODES ACTION TAKEN
DATE
To be filled if RPN>150
I = Date of Implementation C = Classification S = Severity

11 of 12
 Hindustan Malleable Casting Works POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)
EICHER TRACTORS (A Unit of Tafe Motors and
Part Name FLY WHEEL CASING Customer PFMEA No. HMCW/TMTL-01 Rev. No. 0
Tractors Limited)
Part No. 9701 063 1 Key Dates Date 22/05/08 Date 22/05/08

Core Team Vishnu Agarwal, Ankur Agarwal, Jagat Singh

RES. &
S. COMPONENT POTENTIAL FAILURE RECOM. ACTION

RPN

RPN
S C FAILURE EFFECTS FAILURE CAUSES O FAILURE PREVENTION FAILURE DETECTION D TARGET S O D
No. OR PROCESS FUNCTION MODES ACTION TAKEN
DATE

Excessive 7 Pitting over Surface More Blasting Time 4 Inprocess Inspection Visual Inspection 4 112

5 Shot Blasting Blasting

Poor 7 Loose Sand Less Blasting Time 4 Inprocess Inspection Visual Inspection 4 112

More Grinding Force, More

Excessive 7 Shape Lost Grinding Cut, Unskilled 4 Inprocess Inspection Visual Inspection 4 112
Operator
Grinding
6 Grinding
Process Old / Broken Grinding
Wheel, Less Grinding Force,
Poor 7 Excessive Material Remained 4 Inprocess Inspection Visual Inspection 4 112
Less Grinding Cut, Unskilled
Operator

Cost Increases, Poor

Excessive 5 Improper Processing 4 Inprocess Inspection Visual Inspection 4 80
Adhesiveness of Paint
7 Painting Grinding

Poor 5 Increases Rework Improper Processing 5 Inprocess Inspection Visual Inspection 4 100

Dim. Oversize /
7 Increase Rework Improper Processing 3 Inprocess Inspection Sampling PDI 4 84
Inspection Undersize
Final
8
Inspection
Visual Casting
7 Casting Rejection Improper Processing 3 Inprocess Inspection Sampling PDI 4 84
Inspection Defects

O = Failure occurrence probability D = Failure detection probability Risk Priority Number RPN = S x O x D
To be filled if RPN>150
I = Date of Implementation C = Classification S = Severity

12 of 12