PFMEA REVISION HISTORY

Part Name:- Flywheel ASM Customer :- ISUZU MOTORS INDIA PVT LTD
Part No & Rev - 8974450630 Model :-
Sign
Sr No Last Rev & Date Latest Rev Review Date Revision History / Description Remarks
Engg QA Prod

Himanshu Pradeep
01 ----- 00 05.05.2017 Initial FMEA made R.S. Shekhawat
Duniwal Garg

Himanshu Pradeep
02 00 & 05.05.2017 01 26.08.2017 Revised against customer complain R.S. Shekhawat
Duniwal Garg

Vineet Pradeep
03 01 & 26.08.2021 02 27.10.2021 Revised against internal Review R.S. Shekhawat
Upadhyay Garg
 Doc. No. PDC-EPD-F03

PROCESS FAILURE MODE AND EFFECTS ANALYSIS Rev. No. (Date) 00 (01/09/2019)

Issue No. (Date) 02 (01/09/2019)

PFMEA Number 8941725283 FMEA-MCD-110-170 Key Contact / Phone Name / Works / Dept Team Member Department
Rev. No. (Date) 02(27/10/2021) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) 05.05.2017 Mr. Suraj Rawat GM- QA & QC
Part Number 8941725291 Mr. Pradeep garg GM- Operation
Process Responsibility: Core Team
Part Name / Description Flywheel ASM Mr. Arjun Yadav Manager Quality Machine Shop
Material Grade FC 230 Key Date : 5-May-17 Mr. Vineet Upadhyay Sr. Engineer QA

Current Process Controls Action Results

Proce Recommen Responsibilit
Potential Failure
Process Function / Requirements ss Potential Effect(s) of Failure B. No S C Potential Cause(s) / Mechanism(s) of Failure O D RPN ded y & Target
Mode
No. Actions Date
Prevention Detection Actions Taken S O D RPN

Rejection Increases,
More 6 3 5 90
Assembly Problems
Incorrect Set up of Fixture, loose Set up Approval, In Process
Inner Diameter Ø 50.8 / 51.2 mm 1 Process Controlled
Mounting/Clamping, Faulty Tool Travel , Tool Wear Inspection, Operator Monitoring
Rework Increases,
Less 5 3 5 75
Assembly Problems

Rejection Increases,
More 7 3 4 84
Assembly Problems Incorrect Set up of Fixture, loose Set up Approval, In Process
Ø 95.000 / 95.040
Inner Diameter
mm
2 ●▼ Mounting/Clamping, Faulty Tool Travel , Tool Process Controlled Inspection, Operator
Rework Increases, Wear Monitoring,SPC Analysis
Less 7 3 4 84
Assembly Problems
110
Rework Increases,
More 5 3 6 90
Assembly Problems
Ø 110.7 / 111.3 Incorrect Set up of Fixture, loose Set up Approval, In Process
Outer Diameter 3 Program Controlled
mm Mounting/Clamping, Faulty Tool Travel , Tool Wear Inspection
Rejection Increases,
Less 5 3 6 90
Assembly Problems

Rejection Increases,
More 5 3 6 90
Assembly Problems
Ø 229.00 / 232.00 Incorrect Set up of Fixture, loose
Inner Diameter 4 Pattern Controlled Set up Approval
mm Mounting/Clamping, Faulty Tool Travel , Tool Wear
Rework Increases,
Less 5 3 6 90
Assembly Problems

3
Incorrect Set up of Fixture, loose Set up Approval, Operator
Balancinh Hole Ø 250.0 ± 0.50 Rejection Increases,
PCD mm
150 More/Less
Assembly Problems
5 7 ▼ Mounting/Clamping, Faulty Tool Travel , Tool Program Controlled Monitoring, In-Process 5 105
Wear Inspection
3

Rework Increases,
More 6 3 4 72
Assembly Problems Incorrect Set up of Fixture, loose Set up Approval, In Process
Ø 271.30 / 271.40
Outer Diameter
mm
6 ●▼ Mounting/Clamping, Faulty Tool Travel , Tool Process Controlled Inspection, Operator
Rejection Increases, Wear Monitoring,SPC Analysis
Less 6 3 4 72
Assembly Problems
110
Rework Increases,
More 5 3 6 90
Assembly Problems
Ø 275.5 / 276.5 Incorrect Set up of Fixture, loose
Outer Diameter 7 Program Controlled Set up Approval
mm Mounting/Clamping, Faulty Tool Travel , Tool Wear
Rejection Increases,
Less 5 3 6 90
Assembly Problems

Rework Increases,
More 5 3 6 90
Assembly Problems
Ø 296.70 / 297.30 Incorrect Set up of Fixture, loose Set up Approval, In Process
Outer Diameter
mm
120 8
Mounting/Clamping, Faulty Tool Travel , Tool Wear
Program Controlled
Inspection
Rejection Increases,
Less 5 3 6 90
Assembly Problems

Rejection Increases,
Less 6 3 6 108
Assembly Problems
Incorrect Set up of Fixture, loose
Depth 16.50 / 18.00 mm 9 Process Controlled Set up Approval
Mounting/Clamping, Faulty Tool Travel , Tool Wear
Rework Increases,
More 5 3 6 90
Assembly Problems

Rejection Increases, Incorrect Set up of Fixture, loose

Radius R10 More 12 4 3 Program Controlled Set up Approval 7 84
Assembly Problems Mounting/Clamping, Faulty Tool Travel , Tool Wear

Rework Increases,
Less 4 3 7 84
Assembly Problems Incorrect Set up of Fixture, loose
Chamfer 1.5 X 45° 110 13 Program Controlled Set up Approval
Rejection Increases, Mounting/Clamping, Faulty Tool Travel , Tool Wear
More 4 3 7 84
Assembly Problems

Rejection Increases, Incorrect Set up of Fixture, loose

Radius R0.8 More 14 4 3 Program Controlled Set up Approval 7 84
Assembly Problems Mounting/Clamping, Faulty Tool Travel , Tool Wear

Rejection Increases, Incorrect Set up of Fixture, loose

Angle 30° More / Less 15 7 3 Pattern Controlled 4 84
Assembly Problems Mounting/Clamping, Faulty Tool Travel , Tool Wear

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

PROCESS FAILURE MODE AND EFFECTS ANALYSIS Rev. No. (Date) 00 (01/09/2019)

Issue No. (Date) 02 (01/09/2019)

PFMEA Number 8941725283 FMEA-MCD-110-170 Key Contact / Phone Name / Works / Dept Team Member Department
Rev. No. (Date) 02(27/10/2021) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) 05.05.2017 Mr. Suraj Rawat GM- QA & QC
Part Number 8941725291 Mr. Pradeep garg GM- Operation
110 Process Responsibility: Core Team
Part Name / Description Flywheel ASM Mr. Arjun Yadav Manager Quality Machine Shop
Material Grade FC 230 Key Date : 5-May-17 Mr. Vineet Upadhyay Sr. Engineer QA

Current Process Controls Action Results

Proce Recommen Responsibilit
Potential Failure
Process Function / Requirements ss Potential Effect(s) of Failure B. No S C Potential Cause(s) / Mechanism(s) of Failure O D RPN ded y & Target
Mode
No. Actions Date
Prevention Detection Actions Taken S O D RPN
Rejection Increases, Incorrect Set up of Fixture, loose
Angle 30° More / Less 15 7 3 Pattern Controlled 4 84
Assembly Problems Mounting/Clamping, Faulty Tool Travel , Tool Wear

Rejection Increases, Incorrect Set up of Fixture, loose

Radius R3.0 More 16 4 3 Program Controlled Set up Approval 7 84
Assembly Problems Mounting/Clamping, Faulty Tool Travel , Tool Wear

Rework Increases,
Less 5 3 7 105
Assembly Problems Incorrect Set up of Fixture, loose
Chamfer 17 Program Controlled Set up Approval
0.5 X 45° Rejection Increases, Mounting/Clamping, Faulty Tool Travel , Tool Wear
More 5 3 7 105
Assembly Problems

Program & Process

Rejection Increases, Incorrect Set up of Fixture, loose Set up Approval , Inprocess
Surface Finish 3.2 µRa More 18 5 3 Controlled , Tool Life 6 90
Assembly Problems Mounting/Clamping, Faulty Tool Travel , Tool Wear Inspection
Monitoring

Program & Process

Rejection Increases, Incorrect Set up of Fixture, loose
Surface Finish 3.2 - 6.3 µRa More 19 5 3 Controlled , Tool Life Set up Approval 7 105
Assembly Problems Mounting/Clamping, Faulty Tool Travel , Tool Wear
Monitoring

Program & Process

Rejection Increases, Incorrect Set up of Fixture, loose
Surface Finish 12.5 - 25 µRa 110 More 20 5 3 Controlled , Tool Life Set up Approval 7 105
Assembly Problems Mounting/Clamping, Faulty Tool Travel , Tool Wear
Monitoring

Program & Process

Rejection Increases, Incorrect Set up of Fixture, loose Set up Approval , Inprocess
Surface Finish 3.2 - 6.3 µRa More 21 5 3 Controlled , Tool Life 7 105
Assembly Problems Mounting/Clamping, Faulty Tool Travel , Tool Wear Inspection
Monitoring

Rework Increases,
Less 5 3 7 105
Assembly Problems
Incorrect Set up of Fixture, loose
Chamfer 1.0 X 45° 22 Program Controlled Set up Approval
Mounting/Clamping, Faulty Tool Travel , Tool Wear
Rejection Increases,
More 5 3 7 105
Assembly Problems

Rejection Increases, Incorrect Set up of Fixture, loose

Radius R0.2/0.5 More 23 4 3 Program Controlled Set up Approval 7 84
Assembly Problems Mounting/Clamping, Faulty Tool Travel , Tool Wear

Program & Process

Rejection Increases, Incorrect Set up of Fixture, loose Set up Approval , Inprocess
Surface Finish 3.2 - 6.3 µRa More 24 5 3 Controlled , Tool Life 6 90
Assembly Problems Mounting/Clamping, Faulty Tool Travel , Tool Wear Inspection
Monitoring

Program & Process

Rejection Increases, Incorrect Set up of Fixture, loose
Surface Finish 12.5 - 25 µRa 120 More
Assembly Problems
25 5
Mounting/Clamping, Faulty Tool Travel , Tool Wear
3 Controlled , Tool Life Set up Approval 7 105
Monitoring

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

PROCESS FAILURE MODE AND EFFECTS ANALYSIS Rev. No. (Date) 00 (01/09/2019)

Issue No. (Date) 02 (01/09/2019)

PFMEA Number 8941725283 FMEA-MCD-110-170 Key Contact / Phone Name / Works / Dept Team Member Department
Rev. No. (Date) 02(27/10/2021) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) 05.05.2017 Mr. Suraj Rawat GM- QA & QC
Part Number 8941725291 Mr. Pradeep garg GM- Operation
Process Responsibility: Core Team
Part Name / Description Flywheel ASM Mr. Arjun Yadav Manager Quality Machine Shop
Material Grade FC 230 Key Date : 5-May-17 Mr. Vineet Upadhyay Sr. Engineer QA

Current Process Controls Action Results

Proce Recommen Responsibilit
Potential Failure
Process Function / Requirements ss Potential Effect(s) of Failure B. No S C Potential Cause(s) / Mechanism(s) of Failure O D RPN ded y & Target
Mode
No. Actions Date
Prevention Detection Actions Taken S O D RPN

Rejection Increases,
Less 5 3 6 90
Assembly Problems
Incorrect Set up of Fixture, loose
Depth 4.7 / 6.2 mm 26 Program Controlled Set up Approval
Mounting/Clamping, Faulty Tool Travel , Tool Wear
Rework Increases,
More 5 3 6 90
Assembly Problems

Rejection Increases, Incorrect Set up of Fixture, loose

Surface Finish 3.2 - 6.3 µRa More 27 4 3 Program Controlled Set up Approval 7 84
Assembly Problems Mounting/Clamping, Faulty Tool Travel , Tool Wear

Rejection Increases,
Less 6 3 5 90
Assembly Problems Incorrect Set up of Fixture, loose
Set up Approval, In Process
Depth 12.5 / 12.7 mm 110 28 ▼ Mounting/Clamping, Faulty Tool Travel , Tool Program Controlled
Inspection
Rework Increases, Wear
More 5 3 5 75
Assembly Problems

Rejection Increases,
Less 6 3 5 90
Assembly Problems Incorrect Set up of Fixture, loose
Set up Approval, In Process
Depth 1.40 / 1.60 mm 29 ▼ Mounting/Clamping, Faulty Tool Travel , Tool Program Controlled
Inspection
Rework Increases, Wear
More 5 3 5 75
Assembly Problems

Rejection Increases,
Less 6 3 5 90
Assembly Problems
Incorrect Set up of Fixture, loose Set up Approval, In Process
Depth 6.80 / 7.20 mm 30 Program Controlled
Mounting/Clamping, Faulty Tool Travel , Tool Wear Inspection
Rework Increases,
More 5 3 5 75
Assembly Problems

Rejection Increases,
Less 6 3 5 90
Assembly Problems Incorrect Set up of Fixture, loose
Set up Approval, In Process
Total Height 61.90 / 62.10 mm 31 ▼ Mounting/Clamping, Faulty Tool Travel , Tool Program Controlled
Inspection
Rework Increases, Wear
More 6 3 5 90
Assembly Problems

Rejection Increases,
Less 6 3 5 90
Assembly Problems Incorrect Set up of Fixture, loose
Set up Approval, In Process
Depth 41.9 / 42.1 mm 32 ▼ Mounting/Clamping, Faulty Tool Travel , Tool Program Controlled
Inspection
Rework Increases, Wear
More 6 3 5 90
Assembly Problems

Rejection Increases,
Less 5 3 6 90
Assembly Problems
Incorrect Set up of Fixture, loose
Depth 7.8 / 8.2 mm 33 Program Controlled Set up Approval
Mounting/Clamping, Faulty Tool Travel , Tool Wear
Rework Increases,
More 5 3 6 90
120 Assembly Problems

Rejection Increases,
Less 5 3 6 90
Assembly Problems
Incorrect Set up of Fixture, loose
Depth 33.70 / 34.30 mm 34 Program Controlled Set up Approval
Mounting/Clamping, Faulty Tool Travel , Tool Wear
Rework Increases,
More 5 3 6 90
Assembly Problems

Rejection Increases,
Less 5 3 6 90
Assembly Problems
Incorrect Set up of Fixture, loose
Depth 17.3 / 17.8 mm 35 Program Controlled Set up Approval
Mounting/Clamping, Faulty Tool Travel , Tool Wear
Rework Increases,
More 5 3 6 90
Assembly Problems

Rejection Increases,
Less 5 3 6 90
Assembly Problems
Incorrect Set up of Fixture, loose Set up Approval, In Process
Width 15.3 / 15.7 mm 36 Program Controlled
Mounting/Clamping, Faulty Tool Travel , Tool Wear Inspection
Rework Increases,
More 5 3 6 90
Assembly Problems

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

PROCESS FAILURE MODE AND EFFECTS ANALYSIS Rev. No. (Date) 00 (01/09/2019)

Issue No. (Date) 02 (01/09/2019)

PFMEA Number 8941725283 FMEA-MCD-110-170 Key Contact / Phone Name / Works / Dept Team Member Department
Rev. No. (Date) 02(27/10/2021) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) 05.05.2017 Mr. Suraj Rawat GM- QA & QC
Part Number 8941725291 Mr. Pradeep garg GM- Operation
Process Responsibility: Core Team
Part Name / Description Flywheel ASM Mr. Arjun Yadav Manager Quality Machine Shop
Material Grade FC 230 Key Date : 5-May-17 Mr. Vineet Upadhyay Sr. Engineer QA

Current Process Controls Action Results

Proce Recommen Responsibilit
Potential Failure
Process Function / Requirements ss Potential Effect(s) of Failure B. No S C Potential Cause(s) / Mechanism(s) of Failure O D RPN ded y & Target
Mode
No. Actions Date
Prevention Detection Actions Taken S O D RPN

Program & Process

Rejection Increases, Incorrect Set up of Fixture, loose
Surface Finish 3.2 - 6.3 µRa More 37 5 3 Controlled , Tool Life Set up Approval 7 105
Assembly Problems Mounting/Clamping, Faulty Tool Travel , Tool Wear
Monitoring

Program & Process

Rejection Increases, Incorrect Set up of Fixture, loose Set up Approval, In Process
Surface Finish 3.2 - 6.3 µRa More 38 6 3 Controlled , Tool Life 6 108
Assembly Problems Mounting/Clamping, Faulty Tool Travel , Tool Wear Insppection
Monitoring

Rejection Increases, Incorrect Set up of Fixture, loose

Groove Depth 0.0 -1.0 mm More 39 5 3 Program Controlled Set Up Approval 7 105
120 Assembly Problems Mounting/Clamping, Faulty Tool Travel , Tool Wear

0.07 TIR MAX.

Rejection Increases, Assembly Program & Process
Parallesim with Ref. 'C' on More
Problems
40 7 ▼ Dents in Jaws, Chips b/w butting area and jaws 3
Controlled
Set Up Approval/ 1/Shift 6 126
Ø 225 mm

Program & Process

Rejection Increases, Incorrect Set up of Fixture, loose
Surface Finish 12.5 - 25 µRa More 41 5 3 Controlled , Tool Life Set up Approval 7 105
Assembly Problems Mounting/Clamping, Faulty Tool Travel , Tool Wear
Monitoring

Rejection Increases,
Less 6 3 6 108
Assembly Problems
Incorrect Set up of Fixture, loose
Ream Depth 9.80 / 10.20 mm 130 42
Mounting/Clamping, Faulty Tool Travel , Tool Wear
Program Controlled Set up Approval
Rework Increases,
More 5 3 6 90
Assembly Problems

Program & Process

Rejection Increases, Incorrect Set up of Fixture, loose
Surface Finish 12.5 - 25 µRa 120 More
Assembly Problems
43 5
Mounting/Clamping, Faulty Tool Travel , Tool Wear
3 Controlled , Tool Life Set up Approval 7 105
Monitoring

Rejection Increases,
Less 6 3 6 108
Assembly Problems
Incorrect Set up of Fixture, loose
Drill Depth 13.80 /14.20 mm 130 44
Mounting/Clamping, Faulty Tool Travel , Tool Wear
Program Controlled Set up Approval
Rework Increases,
More 6 3 6 108
Assembly Problems

Program & Process

Rejection Increases, Incorrect Set up of Fixture, loose Set up Approval , Inprocess
Surface Finish 3.2 - 6.3 µRa More 45 5 3 Controlled , Tool Life 6 90
Assembly Problems Mounting/Clamping, Faulty Tool Travel , Tool Wear Inspection
Monitoring

Rejection Increases,
More 5 3 7 105
Assembly Problems
Ø 117.7 / 118.3 Incorrect Set up of Fixture, loose
Inner Diameter 46 Program Controlled Set up Approval
mm Mounting/Clamping, Faulty Tool Travel , Tool Wear
Rework Increases,
Less 5 3 7 105
Assembly Problems

Rejection Increases,
More 6 3 6 108
Assembly Problems
Ø 135.50 / 136.50 Incorrect Set up of Fixture, loose
Inner Diameter 47 Pattern Controlled Set up Approval
mm 120 Mounting/Clamping, Faulty Tool Travel , Tool Wear
Rework Increases,
Less 6 3 6 108
Assembly Problems

Rejection Increases,
More 6 3 6 108
Assembly Problems
Ø 149.0 / 151.00 Incorrect Set up of Fixture, loose
Inner Diameter 48 Program Controlled Set up Approval
mm Mounting/Clamping, Faulty Tool Travel , Tool Wear
Rework Increases,
Less 6 3 6 108
Assembly Problems

Rejection Increases,
More 6 3 6 108
Assembly Problems
Groove Inner Ø 229.5 / 230.5 Incorrect Set up of Fixture, loose
49 Program Controlled Program Controlled
Diameter mm Mounting/Clamping, Faulty Tool Travel , Tool Wear
Rework Increases,
Less 6 3 6 108
Assembly Problems

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

PROCESS FAILURE MODE AND EFFECTS ANALYSIS Rev. No. (Date) 00 (01/09/2019)

Issue No. (Date) 02 (01/09/2019)

PFMEA Number 8941725283 FMEA-MCD-110-170 Key Contact / Phone Name / Works / Dept Team Member Department
Rev. No. (Date) 02(27/10/2021) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) 05.05.2017 Mr. Suraj Rawat GM- QA & QC
Part Number 8941725291 Mr. Pradeep garg GM- Operation
Process Responsibility: Core Team
Part Name / Description Flywheel ASM Mr. Arjun Yadav Manager Quality Machine Shop
Material Grade FC 230 Key Date : 5-May-17 Mr. Vineet Upadhyay Sr. Engineer QA

Current Process Controls Action Results

Proce Recommen Responsibilit
Potential Failure
Process Function / Requirements ss Potential Effect(s) of Failure B. No S C Potential Cause(s) / Mechanism(s) of Failure O D RPN ded y & Target
Mode
No. Actions Date
Prevention Detection Actions Taken S O D RPN

Rejection Increases,
More 6 3 5 90
Assembly Problems
Ø 234.5 / 235.5 Incorrect Set up of Fixture, loose Set up Approval, In Process
Inner Diameter 50 Program Controlled
mm Mounting/Clamping, Faulty Tool Travel , Tool Wear Inspection
Rework Increases,
Less 6 3 5 90
Assembly Problems
120
Rework Increases,
More 6 3 5 90
Assembly Problems
Ø 290.5 / 291.5 Incorrect Set up of Fixture, loose
Outer Diameter 51 Program Controlled Set up Approval
mm Mounting/Clamping, Faulty Tool Travel , Tool Wear
Rejection Increases,
Less 6 3 5 90
Assembly Problems

Rework Increases,
Less 5 3 7 105
Assembly Problems Incorrect Set up of Fixture, loose
Chamfer 130 52 Program Controlled Set up Approval
0.5 X 45° Rejection Increases, Mounting/Clamping, Faulty Tool Travel , Tool Wear
More 5 3 7 105
Assembly Problems

53
Rejection Increases, Incorrect Set up of Fixture, loose
Radius R3.0 More & 5 2 Pattern Controlled Set up Approval 6 60
Assembly Problems Mounting/Clamping, Faulty Tool Travel , Tool Wear
54

55 Program & Process

Rejection Increases, Incorrect Set up of Fixture, loose
Surface Finish 12.5 - 25 µRa More & 5 3 Controlled , Tool Life Set up Approval 7 105
120 Assembly Problems Mounting/Clamping, Faulty Tool Travel , Tool Wear
56 Monitoring

Rejection Increases, Incorrect Set up of Fixture, loose

Angle 2° More / Less 57 5 3 Program Controlled Program Controlled 7 105
Assembly Problems Mounting/Clamping, Faulty Tool Travel , Tool Wear

Drill Dia Incorrect Set up of Fixture, loose

More Rejection Increases 4 3 Process Controlled Set up Approval 4 48
ɸ12.70 Max Mounting/Clamping, Faulty Tool Travel , Tool Wear

Drill Depth Incorrect Set up of Fixture, loose

150 More Rejection Increases 58 4 3 Process Controlled Set up Approval 4 48
22.00 Max. Mounting/Clamping, Faulty Tool Travel , Tool Wear

Incorrect Set up of Fixture, loose

Wall Thickness 20.0mm Min. Less Rejection Increases 4 3 Process Controlled Set up Approval 4 48
Mounting/Clamping, Faulty Tool Travel , Tool Wear

67 Incorrect Set up of Fixture, loose

Rejection Increases, Program & Process Set up Approval , In process
Center Distance 62.70 / 62.80 mm More / Less
Assembly Problems
& 7 ▼ Mounting/Clamping, Faulty Tool Travel , Tool 3
Controlled inspection ,Operator Monitoring
5 105
71 Wear

68 Incorrect Set up of Fixture, loose

108.640 / 108.740 Rejection Increases, Program & Process Set up Approval , In process
Center Distance
mm
More / Less
Assembly Problems
& 7 ▼ Mounting/Clamping, Faulty Tool Travel , Tool 3
Controlled inspection ,Operator Monitoring
5 105
69 Wear

130

Rejection Increases, Incorrect Set up of Fixture, loose Program & Process

Center Distance 134.70 Ref. More / Less 70 6 3 Set up Approval, CMM Inspection 6 108
Assembly Problems Mounting/Clamping, Faulty Tool Travel , Tool Wear Controlled

Incorrect Set up of Fixture, loose

125.45 / 125.55 Rejection Increases, Program & Process Set up Approval , In process
Center Distance
mm
More / Less
Assembly Problems
72 7 ▼ Mounting/Clamping, Faulty Tool Travel , Tool 3
Controlled inspection ,Operator Monitoring
5 105
Wear

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

PROCESS FAILURE MODE AND EFFECTS ANALYSIS Rev. No. (Date) 00 (01/09/2019)

Issue No. (Date) 02 (01/09/2019)

PFMEA Number 8941725283 FMEA-MCD-110-170 Key Contact / Phone Name / Works / Dept Team Member Department
Rev. No. (Date) 02(27/10/2021) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) 05.05.2017 Mr. Suraj Rawat GM- QA & QC
Part Number 8941725291 Mr. Pradeep garg GM- Operation
Process Responsibility: Core Team
Part Name / Description Flywheel ASM Mr. Arjun Yadav Manager Quality Machine Shop
Material Grade FC 230 Key Date : 5-May-17 Mr. Vineet Upadhyay Sr. Engineer QA

Current Process Controls Action Results

Proce Recommen Responsibilit
Potential Failure
Process Function / Requirements ss Potential Effect(s) of Failure B. No S C Potential Cause(s) / Mechanism(s) of Failure O D RPN ded y & Target
Mode
No. Actions Date
Prevention Detection Actions Taken S O D RPN

3
Incorrect Set up of Fixture, loose Set up Approval, Operator
Rejection Increases,
PCD Ø 74.00 mm More/Less
Assembly Problems
73 7 ▼ Mounting/Clamping, Faulty Tool Travel , Tool Program Controlled Monitoring, In-Process 5 105
Wear Inspection
3

Rejection Increases, Incorrect Set up of Fixture, loose

Radius R120.0 mm More / Less 74 4 3 Program Controlled Program Controlled 7 84
Assembly Problems Mounting/Clamping, Faulty Tool Travel , Tool Wear

3
Incorrect Set up of Fixture, loose Set up Approval, Operator
Rejection Increases,
PCD Ø 251.00 mm More/Less
Assembly Problems
75 7 ▼ Mounting/Clamping, Faulty Tool Travel , Tool Program Controlled Monitoring, In-Process 5 105
Wear Inspection
3

Rejection Increases, Incorrect Set up of Fixture, loose

Angle 13.50° More / Less 76 6 3 Program Controlled Set up Approval, CMM Inspection 6 108
Assembly Problems Mounting/Clamping, Faulty Tool Travel , Tool Wear

Incorrect Set up of Fixture, loose Set up Approval, Operator

Rejection Increases,
Angle 73°20' / 73°40' More / Less
Assembly Problems
77 6 ▼ Mounting/Clamping, Faulty Tool Travel , Tool 3 Program Controlled Monitoring, In-Process 5 90
Wear Inspection

78
Rejection Increases, Incorrect Set up of Fixture, loose
Angle 120 ° More / Less
Assembly Problems
& 5
Mounting/Clamping, Faulty Tool Travel , Tool Wear
3 Program Controlled Set up Approval 6 90
79

130 Rejection Increases,

More 7
Assembly Problems Incorrect Set up of Fixture, loose Set up Approval, Operator
Mounting Hole Ø 13.35 / 13.65
Dia. mm
80 ▼ Mounting/Clamping, Faulty Tool Travel , Tool 3 Program Controlled Monitoring, In-Process 5 105
Rework Increases, Wear Inspection
Less 7
Assembly Problems

Rejection Increases, Assembly

Over Size 7 3 5
Problems
Process Controlled Set up Approval , In process
6 Tap Holes M8 X 1.25 ▼ Faulty tool travel, Tool Wear, Tool Run out
& Tool Life Study inspection ,Operator Monitoring
105
Rework increases, Assembly
Under Size 7 3 5
Problems

3 6 126
Rejection Increases, Incorrect Set up of Fixture, loose Set up Approval , In process
Tap Depth 16.0 mm Min. More / Less 7 Program Controlled
Assembly Problems Mounting/Clamping, Faulty Tool Travel , Tool Wear inspection
3 6 0

81
3 6 126
Rejection Increases, Incorrect Set up of Fixture, loose Set up Approval , In process
Drill Depth 20.0 mm Min. More / Less 7 Program Controlled
Assembly Problems Mounting/Clamping, Faulty Tool Travel , Tool Wear inspection
3 6 0

Rework Increases,
Less 5 3 7 105
Assembly Problems
Incorrect Set up of Fixture, loose
Chamfer 90° Ø 8.5 Program Controlled Set up Approval
Mounting/Clamping, Faulty Tool Travel , Tool Wear
Rejection Increases,
More 5 3 7 105
Assembly Problems

Rejection Increases,
More 6 3 5
Assembly Problems Incorrect Set up of Fixture, loose
Ø 5.974 / 5.988 Set up Approval, In Process
3 Dowel Hole Dia.
mm
82 ▼ Mounting/Clamping, Faulty Tool Travel , Tool Process Controlled
Inspection, Operator Monitoring
90
Rework Increases, Wear
Less 6 3 5
Assembly Problems

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

PROCESS FAILURE MODE AND EFFECTS ANALYSIS Rev. No. (Date) 00 (01/09/2019)

Issue No. (Date) 02 (01/09/2019)

PFMEA Number 8941725283 FMEA-MCD-110-170 Key Contact / Phone Name / Works / Dept Team Member Department
Rev. No. (Date) 02(27/10/2021) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) 05.05.2017 Mr. Suraj Rawat GM- QA & QC
Part Number 8941725291 Mr. Pradeep garg GM- Operation
Process Responsibility: Core Team
Part Name / Description Flywheel ASM Mr. Arjun Yadav Manager Quality Machine Shop
Material Grade FC 230 Key Date : 5-May-17 Mr. Vineet Upadhyay Sr. Engineer QA

Current Process Controls Action Results

Proce Recommen Responsibilit
Potential Failure
Process Function / Requirements ss Potential Effect(s) of Failure B. No S C Potential Cause(s) / Mechanism(s) of Failure O D RPN ded y & Target
Mode
No. Actions Date
Prevention Detection Actions Taken S O D RPN

Rejection Increases,
Radius R3.0 More 83 4 Pattern Wear Out 2 Pattern Controlled Set up Approval 7 56
Assembly Problems

Rejection Increases,
Radius R3.0 More 84 4 Pattern Wear Out 2 Pattern Controlled Set up Approval 7 56
Assembly Problems

Dimension (2.0) mm More / Less Rejection Increase 85 4 Pattern Wear Out 2 Pattern Controlled Set up Approval 7 56

Rejection Increases, Incorrect Set up of Fixture, loose

Radius R3.0 More 86 4 2 Pattern Controlled Set up Approval 7 56
Assembly Problems Mounting/Clamping, Faulty Tool Travel , Tool Wear

Rejection Increases,
Radius R18.0 More 87 4 Pattern Wear Out 2 Pattern Controlled Set up Approval 7 56
Assembly Problems

130 Rejection Increases,

Dimension 43.00 / 47.00 mm More / Less 88 5 Pattern Wear Out 3 Pattern Controlled Set Up Approval 7 105
Assembly Problems

Rejection Increases,
Dimension 18.50 / 21.50 mm More / Less 89 5 Pattern Wear Out 3 Pattern Controlled Set Up Approval 7 105
Assembly Problems

Rejection Increases,
Angle 15° More / Less
Assembly Problems
90 4 Pattern Wear Out 3 Pattern Controlled Set Up Approval 7 84

Rejection Increases,
Less 5 3 6 90
Assembly Problems
Incorrect Set up of Fixture, loose
Depth 6.80 / 9.20 mm 91 Program Controlled Set up Approval
Mounting/Clamping, Faulty Tool Travel , Tool Wear
Rework Increases,
More 5 3 6 90
Assembly Problems

Rejection Increases,
Less 5 3 5 75
Assembly Problems
Incorrect Set up of Fixture, loose Set up Approval, In-Process
Depth 16.80 / 19.20 mm 92 Program Controlled
Mounting/Clamping, Faulty Tool Travel , Tool Wear Inspection
Rework Increases,
More 5 3 5 75
Assembly Problems

Chamfered Side Of Ring Gear Teeth Set Up Approval, Operator

Down Side Rejection Increase N/A. 7 Operator Negligence 3 Work Instruction 4 84
To Be on Top Side monitoring

Less Assembly Problem 7 2 4 56

Temperature Control
Induction Heater Temperature Sensor setting not proper, Sensor showing wrong Set Up Approval & Operator
140˚ - 150˚ C Changes in Chemical and
N/A. ▼ reading
Meter, Calibration of
Monitoring
140 More 7 2 Digital meter 4 56
Mechanical Properties

Assembly Problem, Rework

Less 7 2 4 56
Increase
Pressing Load Operator Negligence/ gauge Malfunction/ Set UP Approval & Operator
49 KN/5 Ton Crack Problem & Rejection
N/A. ▼ Equipment Malfunction
Trained Operator
Monitoring
More 7 2 4 56
Increase

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

PROCESS FAILURE MODE AND EFFECTS ANALYSIS Rev. No. (Date) 00 (01/09/2019)

Issue No. (Date) 02 (01/09/2019)

PFMEA Number 8941725283 FMEA-MCD-110-170 Key Contact / Phone Name / Works / Dept Team Member Department
Rev. No. (Date) 02(27/10/2021) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) 05.05.2017 Mr. Suraj Rawat GM- QA & QC
Part Number 8941725291 Mr. Pradeep garg GM- Operation
Process Responsibility: Core Team
Part Name / Description Flywheel ASM Mr. Arjun Yadav Manager Quality Machine Shop
Material Grade FC 230 Key Date : 5-May-17 Mr. Vineet Upadhyay Sr. Engineer QA

Current Process Controls Action Results

Proce Recommen Responsibilit
Potential Failure
Process Function / Requirements ss Potential Effect(s) of Failure B. No S C Potential Cause(s) / Mechanism(s) of Failure O D RPN ded y & Target
Mode
No. Actions Date
Prevention Detection Actions Taken S O D RPN

Assembly Problem, Rework

Less 7 2 4 56
Ring Gear Pressing Holding Dwell Increase Pressing Control Unit
Operator Negligence/ gauge Malfunction/ Set Up Approval & 100%
Time N/A. ▼ Equipment Malfunction
& Operator
Monitoring
Min. 10 Sec. Crack Problem & Rejection Monitoring
More 7 2 4 56
Increase
140

Gap Between Shoulder & Face of Work Instruction,

Set Up Approval, , Operator
Ring Gap Rework Increases N/A. 7 ▼ Operator Negligence 2 Training Provided to
monitoring, Final Inspection
4 56
0.100 operator

Unbalance Mass Set up Approval, In Process

150 More Rejection Increases 15B 4 Operator Negligence 3 Process Controlled 4 48
20 gr-cm Inspection, Operator Monitoring

Cleaning Of Parts
Surface and Holes of the part should Chips & Rust Re Clean & Oiling N/A 4 Operator Negligence 3 Process Controlled Supervisor Monitoring 6 72
be dry and free from the Rust & Chips
160

RPO Filter Frequency Unclean Oil, Dust can stick to

Not changed N/A 5 Operator Negligence 3 Process Controlled Supervisor Monitoring 6 90
7 days holes

Packing
Mishandling Part may get damage N/A 5 Operator Negligence/ Part fall down 3 Trained Operator Supervisor Monitoring 6 90
Single line flow

170

Packing Standard & Supervisor

Packing Quantity Per Box Less or More Supply NA 7 Operator Negligence 3 Process Controlled 2 42
Monitoring

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