PROCESS POTEN

Part Description: STEP ILLUMI (08E12-T5S-7000)

Core Team: Mr. Rakesh, Mr. Prabhjot, Mr. Amarpreet Singh, Mr. Abhimanyu, Mr.

Process: 10 to 70
Process Responsibility: Puneet Sharma
Model : 2WF

Process Function
Requirement

PFMEA NO. : PFMEA-ELEC-008

Potential Cause(s) / Mechanism(s) of

Failure

O
c
c
u
r
r
e
d

Material coming from suppliers not checked

Incoming Material to store

Wrong material grade/ Wrong quantity Customer dissatisfaction

Issued

Operator negligence

Preheating at Low Temp.

Moisture Remains In Material

Operator negligence

Moisture Remains In Material

Operator negligence

Potential Failure Mode

Potential Effect(s) of Failure

S
e
v
e
r
i
t
y

Fuctional Falilure/ Customer Dissatisfaction

C
l
a
s
s

(10)
Material not as per req.

Incoming Inspection of
PCB and Raw Material

LED found fused

(20)

Storage

Material contaminated/ Damage

Parts with reduced quality Customer dissatisfaction

(30)
Parts production in wrong material

Material Issue
(40)

Pre Heating of Plastic Raw

Without Pre Heating
Material

(50)

Shrinkage

Moisture Remains In Material

Low Injection Pressure, Inadequate

Cooling Time and Low Barrel Temp.

Injection Moulding

Flow Marks

Poor Appearance

Low Injection Pressure and Temp.

Flashes

Fitment NG

High Injection Pressure & Temp.

Short Piece

Poor Appearance/ Fitment Problem

Low Melt Temp. and Low Injection

Pressure

(60)

Gate Cutting

Without Gate Cutting

Line Stopage Problem During Assy. Stage

Operator negligence

Deep Cutting Mark

Poor Appearance

Operator negligence

Line Stopage Problem During Assy. Stage

Operator negligence

Sharp Edges

Poor Appearance

Operator negligence

Film Cutting not Proper

Line Stopage Problem During Assy. Stage

Operator negligence

(70)

Quality Inspection

Not Good Material Pass To Next

Stage

(80)

S.S.Strip cutting
(90)

Polyster Film Plotting

PREPARED BY:

CHECKED BY:

CESS POTENTIAL FAILURE MODE & EFFECTS ANALYSIS

h, Mr. Abhimanyu, Mr. Rang Bahadur

PFMEA Date(Org.) : 26/05/14

Rev. Date / Rev. No. : 0
Page: 1 of 3

Current Process Controls

Prevention

Receiving Inspection as per Drawing/

Standard

Action Results

Detection

Visual/ Instrument for Inspection

Material storage at defined area

Visual

D
e
t
e
c
t
i
o
n

R
P
N

63

63

Training to Operators

During Injection Moulding Stage

60

Training to Operators

During Injection Moulding Stage

60

Training to Operators

During Injection Moulding Stage

60

M/C Parameters Checking

Visual

60

M/C Parameters Checking

Visual

60

M/C Parameters Checking

Visual

60

M/C Parameters Checking

Visual

40

Recommended Action(s)

Responsibility & Target

Completion Date

Action
Taken

S
e
v
e
r
i
t
y

O
c
c
u
r
r
e
d

D
e
t
e
c
t
i
o
n

R
P
N

Training to Operators,

Visual

45

Training to Operators,

Visual

45

Training to Operators

Visual

45

Part Matched With Master Sample Visual

63

Part Matched With Master Sample Visual

45

APPROVED BY:

F-QCD-012, REV 00.

PROCESS POTE

Part Description: STEP ILLUMI (08E12-T5S-7000)

Core Team: Mr. Rakesh, Mr. Prabhjot, Mr. Amarpreet Singh, Mr. Abhimanyu,

Process: 80 to 160
Process Responsibility: Puneet Sharma
Model : 2WF

PFMEA NO. : PFMEA-ELEC-008

Process Function
Requirement

Wire Soldering With PCB

Potential Failure Mode

Potential Effect(s) of Failure

S
e
v
e
r
i
t
y

C
l
a
s
s

Potential Cause(s) / Mechanism(s)

of Failure

O
c
c
u
r
r
e
d

Soldering Not Proper

Funtional Failure

Inadequate Operator

Soldering -Wrong Polarity Of Wires

Funtional Failure

Operator negligence

Part get rejected due to visual defects

Parts visualy rejected

Bins not properly cleaned

PCB passed to next stage without testing

Product Rejection Increase at Light Testing

Stage

Operator negligence

Mixing of NG Product with Ok

Product Rejection Increase at Light Testing

Stage

Operator negligence

Not properly assembled

During Ultrasonic Welding Stage getting

Problem

Operator negligence

Ultrasonic Welding Not Proper

Product Rejection Increase

M/c Setting Not Proper

Film Out

Product Rejection Increase

During Film Assy., Assembly Not

Proper

Inspection Not Proper

Chance Of Funtional Failure

Operator negligence

(110)

PCB Placed in bins

(120)

PCB Inspection

Light Body Assembly

(140)

Ultrasonic Welding

Light Inspection

(160)

Light Taping

(170)

Light Passed to next stage without

ventilation Cloth

Line Stopage Problem During Assy. Stage(SS

Strip And Garn)

Operator negligence

Light Passed to next stage without Taping

Line Stopage Problem During Assy. Stage(SS

Strip And Garn)

Operator negligence

Letter Peeling Not Proper

Etching(shot Blasting ) Not Proper-As

Required

Operator negligence

Vinyl Pasting Not Proper

Design On Strip Not Proper

Operator negligence

Shot Blasting Not Proper

Design On Strip Not Proper

Operator negligence

Operator negligence

Front & Rear Garnish SS Strip

Etching

Front Garnish cleaning with

Strip front area should be properly cleaned Product Rejection Increase
IPA
PREPARED BY:

CHECKED BY:

ROCESS POTENTIAL FAILURE MODE & EFFECTS ANALYSIS

Singh, Mr. Abhimanyu, Mr. Rang Bahadur

PFMEA Date(Org.) : 26/05/14

Rev. Date / Rev. No. : 0
Page: 2 of 3

Current Process Controls

Action Results
D
e
t
e
c
t
i
o
n

R
P
N

Training Given for Operator /Provide Fixture for Visual Check , Functional Testing at PCB
soldering
Testing stage

54

Limit Sample,Training Provided,work

Instruction

Functional Testing at PCB Testing stage

54

Bins should be properly cleaned and Foam

should be placed there

Visual checking

54

Work Instruction for PCB Testing,

Functional Testing at Light Testing,Final

Testing stage

54

Using Seprate bins for rejection eg.Red Bin

Functional Testing Light Inspection,Final

Inspection stage

54

Work Instruction,Training to Operators,Limit

Sample

Light Inspection Stage

54

During Initial Job Setup Check Prouct Sealing

Visual At Same Stage, Light Testing Stage

54

Visual,work instruction , Adequate Operator

Visual at same stage ,Light Testing Stage,

Final Testing

54

Work Instruction

Visual / DC Supply

48

Prevention

Detection

Recommended Action(s)

Responsibility & Target

Completion Date

Action
Taken

S
e
v
e
r
i
t
y

O
c
c
u
r
r
e
d

D
e
t
e
c
t
i
o
n

R
P
N

Work Instruction

Visual -Light Pasting with SS Strip stage

36

Work Instruction

Visual -Light Pasting with SS Strip stage

36

Work Instruction, Limit Sample

Visual

54

Work Instuction, Limit Sample

Visual

54

Work Instuction, Limit Sample

Visual

54

Work Instruction

Visual

45

APPROVED BY:

F-QCD-012, REV 00.

PROCESS POTEN

Part Description: STEP ILLUMI (08E12-T5S-7000)

Core Team: Mr. Amarpreet Singh, Mr. Abhimanyu, Mr. Prabhjot Singh, Mr. Rang

Process: 170 to 230

Process Responsibility: Puneet Sharma
Model : 2WF

PFMEA NO. : PFMEA-ELEC-008

Process Function
Requirement

(190)

Front Garnish, Light

assembly and SS Strip Taping

(200)

Assembly of Front Garnish

with SS Strip and Light
Assembly
(210)

Potential Failure Mode

Potential Effect(s) of Failure

S
e
v
e
r
i
t
y

C
l
a
s
s

Potential Cause(s) / Mechanism(s) of

Failure

O
c
c
u
r
r
e
d

Taping Not Proper

Product Rejection Increase

Operator negligence

Tape Size Not Proper

Product Rejection Increase

Operator negligence

Tape not Properly pasted with SS Strip

Assembly Problem -During Assy.with Garn

After tape application, manual pressure not

applied

Gap between Garnish & SS Strip

Product rejection increase

SS Strip not pasted propery on Front

Garnish

Light assembly should be properly pasted Misalignment of light assembly

Light assembly not pasted properly

Polarity of inserted wire wrong

Chance Of Funtional Failure

Operator negligence

Chance of Terminal Removing From Coupler

Operator negligence

Operator negligence

Coupler Assembly For Front Without Locking of Coupler

(220)

Rear Garnish cleaning with

Strip front area should be properly cleaned Product Rejection Increase
IPA
(230)

Taping Not Proper

Product Rejection Increase

Operator negligence

Tape Size Not Proper

Product Rejection Increase

Operator negligence

Tape Missing

Customer Dissatisfaction

Operator negligence

SS Strip Not Pasted properly with GarnAdhesiveness

Customer Dissatisfaction

3M Primer not Applied on Garn before

pasting with SS Strip

Rear Garn Taping

(240)

Assembly Of SS Strip and

Garnish

Not Properly Assembled

Product Rejection Increase

Operator negligence

Inspection Not Proper

Chance Of Funtional Failure

Operator negligence

Cleaning Not Proper

Customer Dissatisfaction

Operator negligence

Packing Contnents Missing

Customer Dissatisfaction

Operator negligence

Late Dispatches

Customer Dissatisfaction

Transportation Problem

Not As per Customer Requirement- Qty.

Customer Dissatisfaction

Material receipt from Production not in time

(250)

Final Inspection
(260)

Packing
(270)

Storage/Dispatch

PREPARED BY:

CHECKED BY:

OCESS POTENTIAL FAILURE MODE & EFFECTS ANALYSIS

abhjot Singh, Mr. Rang Bahadur

PFMEA Date(Org.) : 26/05/14

Rev. Date / Rev. No. : 0
Page: 3 of 3
Current Process Controls

Prevention

Action Results

Detection

D
e
t
e
c
t
i
o
n

R
P
N

Work instruction , Limit Sample

Visual during assembly

54

Work instruction , Limit Sample

Visual during assembly

54

As per work instruction

Visual during assembly

54

As per work Instruction

Visual during assembly

45

As per work Instruction

Visual during assembly

48

Work instruction , Limit Sample

Visual, Final Inspection

42

Work instruction , Limit Sample

Visual, Final Inspection

36

Work Instruction

Visual

45

Work Instruction,Limit Sample

Visual, Final Inspection

54

Work Instruction,Limit Sample

Visual, Final Inspection

54

Work Instruction,Limit Sample

Visual, Final Inspection

42

Using 3M Primer, Work Instruction

Visual ,Final Inspection

42

Recommended Action(s)

Responsibility & Target

Completion Date

Action
Taken

S
e
v
e
r
i
t
y

O
c
c
u
r
r
e
d

D
e
t
e
c
t
i
o
n

R
P
N

Work Instruction,

Visual

54

Work Instruction

Visual / DC Supply

56

Visual

Visual

56

During Packing -using Different Bin for

Different Contnents

Visual and Visual Inspection Stage

42

Timely Co-ordination with concerned Deptt.

70

Timely Co-ordination with concerned Deptt.

70

APPROVED BY:

F-QCD-012, REV 00.