INCOMING INSPECTION FMEA EXAMPLES
Receiving the raw material: - In this process, the raw material is received from the supplier. Also, the inspection process
should be carried out to decide that the raw material received is as per invoice.
Storage of raw material: - This is another crucial step, as it is a part of inventory management.
Blow material of ducts: -The center duct is formed in this process from the raw material supplied, by the process of blow
molding.
De-flashing:- The process is used to remove excess molding compound, flash, or resin bleed from the body of a
molded plastic center and the leads.
The excess compound might be present as a normal characteristic of the mold interface or due to imperfections in the
mold, such as wear. In-process/online inspection: in this inspection process the molded or the dimensional defect can be
kept a check on.
Hole-punching operation: - Holes are punched in to the mold in this operation. Two things should be taken care of while
doing this operation.
1. Hole punching location.
2. Hole punch size
Storage of the molded parts: - in this operation the molded parts are stored, till the assembly operation
1.6 PFMEA for center duct - Example
Process Function C D
S l Potential cause(s) Current Process Current Process e R
Potential Failure Potential Effect(s) of Oc
Sr No e a / Mechanism(s) of controls controls t P
Mode Failure cur
v s Failure Prevention Detection e N
Requirements s c
Next Operation - Difficult to
process the material Visual inspection on
Assly - Part get rejected in the the bags as per the
Raw material not Wrong material
assly. 7 1 -- invoice details while 6 42
as per invoice supply
Customer - Fit and function unloading the
issues at customer end. material
End Customer - Field failure
Next Operation - Difficult to
process the material Visual inspection on
Assly - Part get rejected in the the bags as per the
Raw material not raw material
assly. 7 Wrong grade supply 1 invoice details while 6 42
as per specification specification sheet
Customer - Fit and function unloading the
issues at customer end. material
End Customer - Field failure
Receiving inspection of Next Operation - Difficult to
10
raw material process the material Visual inspection on
Raw material Lot no. / batch no. &
Assly - Part get rejected in the the bags as per the
without grade not mentioned
assly. 7 1 -- invoice details while 6 42
identification and on the raw material
Customer - Fit and function unloading the
traceability bags.
issues at customer end. material
End Customer - Field failure
Next Operation - Difficult to A) Incoming
process the material inspection of the raw
Mixture of coarse &
Assly - Part get rejected in material
Contaminated raw fine granules / foreign
due to poor aesthetics. 4 3 -- B) Inspection during 4 48
material particles / moisture in
Customer - Part get rejected the material usage
the raw material.
due to poor aesthetics. C) Part inspection
End Customer - Dissatisfaction after moulding.
Next Operation - Difficult to Raw material bags
handle the material Improper loading of checked during
Damaged bags Assly - -- 5 the material / tranist 3 -- unloading at the time 4 60
Customer - -- damage of receipt for
Storage of raw End Customer - -- damages.
20
material Next Operation - Difficult to
Supplier end Raw material bags
process the material
improper loading / checked during
Wet bags Assly - -- 5 2 -- 4 40
Material not coverd unloading at the time
Customer - --
during transit. of receipt.
End Customer - --
Next Operation - Part may
reject / poor appearance.
Assly - Difficulty in assly with High blow speed / First piece approval
Flashes / Parting Standard Process
the mating part. 4 Low holding time and 4 and inprocess 4 64
line Flashes Parameter Sheet
Customer - Part rejected due pressure. inspection sheet.
to poor apperance.
End Customer - Dissatisfaction
Next Operation - Part get
reject / poor appearance.
Blow speed low /
Assly - Difficulty in assly with First piece approval
Short Moulding / Barrel temperature Standard Process
the mating part. 4 4 and inprocess 4 64
Fill low / Air pressure low Parameter Sheet
Customer - Part rejected due inspection sheet.
/ Parision short
to poor apperance.
End Customer - Dissatisfaction
Blow moulding of
30 centre duct
Next Operation - Part get 1) Operator
reject / fitment issues. awareness and
Wrong core & punch
Part weight less or Assly - Part get reject / fitment Standard Process training.
5 size / less or more 3 4 60
more issues. Parameter Sheet 2) First piece
parision length.
Customer - Part get rejected. approval and
End Customer - Dissatisfaction inprocess inspection.
1) First piece
Next Operation - Part poor
approval and
appearance.
Water leakage in the inprocess inspection
Water mark on the Assly - Part poor appearance. Standard Process
3 tool / Chiller temp sheet. 2) 0
part Customer - Part poor Parameter Sheet
too low Tool preventive
appearance.
maintenance plan as
End Customer - Dissatisfaction
per checklist.
Next Operation - Part get
Excessive / less reject / fitment issues / poor 1) Operator
deflashing of the appearance. Unskilled operators / awareness and
40 Deflashing of the part parts along parting Assly - Part get reject / fitment 5 Excessive or less 3 -- training. 4 60
line / Flashes in the issues / poor appearance. deflashing 2) Defective sample
fitment areas. Customer - Part get rejected. display.
End Customer - Dissatisfaction
Next Operation - Part get
reject / fitment issues / poor 1) Standard Process 1) Operator
Moulding /
appearance. Unskilled operators / Parameter Sheet awareness and
Online / Inprocess Dimentional
50 Assly - Part get reject / fitment 5 NA Excessive or less 3 2) First piece approval training. 4 60
inspection defects in the
issues / poor appearance. deflashing and inprocess 2) Defective sample
component
Customer - Part get rejected. inspection. display.
End Customer - Dissatisfaction
Next Operation - Part get 1) Operator
reject / fitment issues. awareness and
Hole punching Assly - Part get reject / fitment Hole location marked in training.
5 Unskilled operators 4 4 80
location wrong. issues. the tool. 2) First piece
Customer - Part get rejected. approval and
End Customer - Dissatisfaction inprocess inspection.
Hole punching
60
operation.
Next Operation - Part get 1) Operator
reject / fitment issues. awareness and
Hole punching size Assly - Part get reject / fitment Punch wear out / training.
5 2 -- 5 50
wrong. issues. wrong punch used. 2) First piece
Customer - Part get rejected. approval and
End Customer - Dissatisfaction inprocess inspection.
Next Operation - Part get
1) Operator
reject / fitment issues.
awareness and
Improper storage / Assly - Part get reject / fitment Part storage in poor
70 Storage of parts 4 NA 1 -- training. 5 20
handling issues. condition.
2) Part storage and
Customer - Part get rejected.
handling instructions.
End Customer - Dissatisfaction
Next Operation - Difficult to fit
side duct
Improper heating Assly - Difficult to assemble Manual heating of
6 Unskilled operator 2 --- 5 60
of centre duct the duct. the centre duct.
Customer - Part get rejected.
End Customer - Field failure.
80 Heating of centre duct
Next Operation - Difficult to
assemble the ducts.
Assly - Part get rejected in the
Moulding defects
assly. 6 Unskilled operator 3 --- --- 8 144
in the ducts.
Customer - Fit and function
issues at customer end.
End Customer - Field failure
Next Operation - Part get
rejeted. Operator training /
Side duct fixing in Assly - Part get rejected. inprocess inspection
6 Unskilled operator 2 --- 5 60
wrong direction Customer - Fitment issues at / inspection on
customer end. checking fixture.
Fixing of side ducts & End Customer - --
90 centre duct assembly
Next Operation - Improper
inspection.
fitment of part.
Side duct foam
Assly - Improper fitment of
visible from centre 5 Unskilled operator 3 --- Operator awareness 7 105
part.
duct joint area.
Customer - Part get rejected.
End Customer - --
Next Operation - Part get
rejected. .
Defective centre Operator awareness
Assly - Part get rejected. 6 Unskilled operator 5 --- 8 240
duct assembly / Visual instruction
Customer - Part get rejected.
End Customer - ---
Packaging of centre
100
duct assembly. Next Operation - Part get
rejected.
Operator awareness
Non standard Assly - ---
5 Unskilled operator 1 --- / Packaging 6 30
packaging Customer - Part get rejected /
instruction.
Dissatisfaction
End Customer - ---
