copy of copy of potential (fmea) (original)

Doc # ___QC\FM\009_________________________

Action Taken

S

E

V

O

C

R

Diametetr Up Fitment problem in Next

Operation 2 Insert wear/Setting 1 In Process Inspection 1 2

Diametetr DownFitment problem in Next


Length Up Fitment problem in Next


Length DownFitment problem in Next


OuterDiameter up Fitment not ok in vehical 5 Insert wear/Setting 4 In Process Inspection 2 40

Outer Diameter Down Fitment not ok in vehical 6 Insert wear/Setting 5 In Process Inspection 2 60

Thickness Variation Prblem in Next Operation 4 Setting 2 In Process Inspection 2 16

Height Fitment not ok in vehical 4 Insert wear/Setting 2 In Process Inspection 2 16

Boring Diameter up Fitment not ok in vehical 6 Insert wear/Setting 3 In Process Inspection 1 18

Boring Diameter Down Fitment not ok in vehical 4 Insert wear/Setting 4 In Process Inspection 4 64

Depth up & Down Fitment not ok in vehical 4 Insert wear/Setting 3 In Process Inspection 4 48





Heights Fitment not ok in vehical 4 Setting 1 In Process Inspection 2 8

Thickness Variation Fitment not ok in vehical 6 Setting 5 In Process Inspection 2 60

Run out up Vibration in vehical 4 S.C Setting 5 In Process Inspection 2 40

Concentricity up Vibration in vehical 6 Setting 4 In Process Inspection 4 96

Perpendicularity up Vibration in vehical 4 Setting 2 In Process Inspection 4 32

Hole Dia Up Vibration in vehical 6 Drill Wear 2 In Process Inspection 2 24

PCD Out & True Position Vibration in vehical 6 Setting 2 In Process Inspection 2 24

Spline damage Vibration in vehical 6 Tool Grinding 2 In Process Inspection 2 24

Major Dia up Vibration in vehical 6 Tool Grinding 2 In Process Inspection 2 24

Burr Vibration in vehical 3 Tool Grinding 3 In Process Inspection 2 18

In Process Inspection


Bolt Press Damage Fitment not ok in vehical

PCD Fitment not ok in vehical 3 Burr and Setting Problem 3 In Process Inspection 2 18

Packing Dent Fitment not ok in vehical 6 Seprator 2 In Process Inspection 1 12

StorageUn proper stacking ,

Moisture , Rust6 1 10 60

DeliveryDemaged parts not

accepted by OEM5 Improper stacking on vahicle not filt, Rash driving 5

Stacjing , Instruction ,

Inspection4 100

Prepared By: Approved By: Approved By:

Zaffar Razzaq (Asst. Manager Q.C) Majid Mehmood (Manager Q.C) Mr. Rafi (Manager Production)

S.C

C

L

A

S

Current Process ControlsProcess Function /

RequirementsPotential Failure Mode

Potential Effect(s) of

Failure

S

E

V

R

P

N

Recommended Actions Responsibility

& Target Date

D

E

T

E

Potential Cause(s) / Mechanism(s) of Failure

Action Results

POTENTIAL

FAILURE MODE AND EFFECTS ANALYSIS

(PROCESS FMEA)

Part Name/ Item__Hub Front Axle Corolla_____________

O

C

C

U

Ist Side Machining

FMEA Number ___03________________________

Part # __________43511-12160_____________________ Prepared By __Zaffar Razzaq________________________

Rough Turning& Pre

Drill

Date (Orig) __08-01-2008________________________

Team __Develoment, Production, QC_____________ Date (Rev) ___________________________

OEM _________ Agriauto________________________

Process Responsibility___Production and QC_______

3Drill Wear

2nd Side Machning

Broaching

3Counter & Chamfer Burr Prblem in Next Operation 1 1

D

E

T

R

P

N

Action Results

FMEA Number ___03________________________

Prepared By __Zaffar Razzaq________________________

Date (Orig) __08-01-2008________________________

Date (Rev) ___________________________

Doc # ___QC\FM\009_________________________

Action Taken

S

E

V

O

C

R






















Run out up Vibration in vehical 4 Setting 5 In Process Inspection 2 40










Corbon Cleaning Appereance no Effect 1 1 1 1

Damage Fitment not ok 3 Setting 2 In Process Inspection 2 12

PCD Out & True Position Vibration in vehical 6 Pressure / Setting 1 In Process Inspection 1 6





accepted by OEM5

Improper stacking on vahicle not filt, Rash

driving5


Inspection4 100



Counter & Chamfer Burr Prblem in Next Operation

R

P

N


& Target Date

C

L

A

S


2nd Side Machning

S.C

Date (Orig) __08-01-2008________________________

Team _____Develoment, Production, QC__________ Date (Rev) __________________________

O

C

C

U

Current Process

Controls

Process Function /



Failure

S

E

V

Action Results

FMEA Number ___04________________________

Part # __________43502-87 Z 04_________________ Prepared By __Zaffar Razzaq________________________

6

3

OEM _________IMC______________________


Rough Turning&

Pre Drill

Ist Side Machining

Drill Wear 1 13

POTENTIAL


(PROCESS FMEA)

Part Name/ Item_ Hub S/A Front Axle Cuore Hub___

D

E

T

E

Broaching

1 12

Bolt Press

Seprator 2 In Process InspectionPacking Dent Fitment not ok in vehical

D

E

T

R

P

N

Date (Orig) __08-01-2008________________________

Date (Rev) __________________________

Action Results

FMEA Number ___04________________________


Doc # ___QC\FM\009_________________________

Action Taken

S

E

V






























Chamfer Burr Fitment Problem 3 Tool Grinding 1 1 3







Inspection4 100



POTENTIAL


(PROCESS FMEA)

Part Name/ Item__Hub Front Wheel SF - 310_____________ FMEA Number ___06_______________________

Part # __________43421-63B00________________________ Prepared By __Zaffar Razzaq________________________

OEM _________Pak Suzuki__________________________


Date (Orig) __05-01-2008________________________

Team __Develoment, Production, QC________________ Date (Rev) __________________________

Process Function /



Failure

S

E

V

C

L

A

S


O

C

C

U

Current Process

Controls

2nd Side Machning

S.C

Broaching

Action Results

Rough Turning&

Pre Drill

Ist Side Machining

D

E

T

E

R

P

N


& Target Date

O

C

R

D

E

T

R

P

N

FMEA Number ___06_______________________


Date (Orig) __05-01-2008________________________

Date (Rev) __________________________

Action Results

Doc # ___QC\FM\009____________________

Action Taken

S

E

V

O

C

R






























Chamfer Burr Fitment Problem 3 Tool Grinding 1 1 3





accepted by OEM5

Improper stacking on vahicle not filt, Rash

driving5


Inspection4 100



Date (Orig) __05-01-2008________________________

POTENTIAL


(PROCESS FMEA)

Part Name/ Item__Hub Front Wheel RA - 410____________

Responsibility

& Target Date

C

L

A

S


O

C

C

U

Action Results

FMEA Number ___05________________________

Part # __________43421-76G01_______________________ Prepared By __Zaffar Razzaq________________________

OEM _________Pak Suzuki_________________________

Process Responsibility___Production and QC__

Broaching

Team __Develoment, Production, QC______________

Rough Turning&

Pre Drill

Ist Side Machining

S.C

Date (Rev) ___________________________

Process Function /



Failure

S

E

V

D

E

T

E

R

P

N

Recommended Actions Current Process

Controls

2nd Side Machning

S.C

D

E

T

R

P

N

Date (Orig) __05-01-2008________________________

Action Results

FMEA Number ___05________________________


Date (Rev) ___________________________

Doc # ___QC\FM\009____________________

Action Taken

S

E

V

O

C

R






































Inspection4 100



POTENTIAL


(PROCESS FMEA)

Part Name/ Item__Hub Front Wheel SB______________ FMEA Number ___07_______________________

Part # __________43421-78402____________________ Prepared By __Zaffar Razzaq________________________

OEM _________ Pak Suzuki____________________

Process Responsibility___Production and QC__

Date (Orig) __01-01-2008________________________

Team __Develoment, Production, QC____________ Date (Rev) __________________________

Process Function /



Failure

S

E

V

Action Results

Responsibility

& Target Date

D

E

T

E

R

P

N

Recommended Actions

C

L

A

S


O

C

C

U

Current Process

Controls

1 1 3Prblem in Next Operation 3

Rough Turning&

Pre Drill

Ist Side Machining

Counter & Chamfer Burr Drill Wear

2nd Side Machning

S.C

Broaching

D

E

T

R

P

N

FMEA Number ___07_______________________


Date (Orig) __01-01-2008________________________

Date (Rev) __________________________

Action Results

Part Name/ Item__RA GSL308 _____________

Part # ___ 28100-P76G80______________

OEM ____ Pak Suzuki_______________________________

Team __ Develoment, Production, QC______________________________________________________________________________________________

S

E

Fitment Problem in Next Operation 5 Setting Problem 3 In Process Inspection 7 105



Fitment Problem in Next Operation 3 Setting Problem / Die Wear 4 In Process Inspection 7 84


Appereance Problum not accepted

By OEM.5 Setting Problem / Die Wear 4 In Process Inspection 3 60














Fitment Problem in Next Operation 4 Setting Problem / Electrok Wear 3 In Process Inspection 5 60




Fitment Problem 2 Setting Problem 3 In Process Inspection 5 30

Appereance Problum 4 Setting Problem 3 In Process Inspection 5 60






Doc # ___QC\FM\019________________________ FMEA Number ___14_______________________

Process Responsibility___Production and QC__________________ Prepared By ___Zaffar Razzaq_______________________

POTENTIAL


(PROCESS FMEA)

Process Function / Requirements Potential Failure Mode Potential Effect(s) of Failure

S

E

V

Date (Orig) ___08-01-2008_________________________

Date (Rev) __________________________D

E

T

E

R

P

N

Recommended Actions Responsibility &

Target Date

C

L

A

S


O

C

C

U

Current Process Controls

Shearing 01 Length Up & Down

Action Results

Action Taken

Guide Plate

Blanking Distance Up& Down

Width Up&down

Bending Hight Up & Down

Hight Up & Down

Eliptical Piercing Distance Up& Down

Appereance

Rib Forming Distance Up& Down

Appereance

1st Bending Hight Up & Down

Hight Up & Down

Distance Up& Down

Pan Shape Piercing Hight Up & Down

04 Hole Piercing Distance Up& Down

2nd Bending Hight Up & Down

Bending (Legs) Hight Up & Down

Diameter Up & Down

Legs spoting Spot

Legs Bending Final Distance Up& Down

Hight Up & Down


M8 Bolt Spoting Spot

Diameter Up & Down

Rubber Extension Plate.

Galvanizing Visual

Width Up&down

Shearing Length Up & Down

Width Up&down

Blanking & Hole Piercing Length Up & Down

Distance Up& Down




Appereance Problum 4 Setting Problem 3 In Process Inspection 5 60



















Nut Loose 2 Setting Problem / Electrok Wear 4 In Process Inspection 7 56

Hook Loose 3 Setting Problem / Electrok Wear 3 In Process Inspection 5 45

Fitment Problem in Next Operation Setting Problem 4 In Process Inspection 0












Fitment Problem in Next Operation 5 Setting Problem / Tool Wear 6 In Process Inspection 4 120

Fitment Problem in Next Operation 5 Setting Problem / Dia Wear 4 In Process Inspection 4 80



Diameter Up & Down

M8 Bolt Welding

M8 Bolt Spoting

Extension Rod Plate

Galvanizing Visual

Distance Up& Down


Distance Up& Down


Appereance


Hight Up & Down

Bending Distance Up& Down

Hight Up & Down

Capsule Forming Width Up&down

Diameter Up & Down

Hole Piercing Distance Up& Down

02 Hole Drilling Distance Up& Down

Starightness Straigtness


Diameter Up & Down

M6 Nut Spoting UnProper

Diameter Up & Down

RA G.S.L. Hook

Hook Spoting UnProper

Width Up&down


Hole Peiricing Diameter Up & Down

Shearing Dimension Up& Down

Hight Up & Down

Flaring Diameter Up & Down

Hight Up & Down

Bending Diameter Up & Down

Appereance

Blanking Dimension Up& Down

Pipe Cutting Length Up & Down

RA EXT. Rod Pipe Ø25.4

Bending Plate Side Distance Up& Down

Bending Bush Side Dimension Up& Down

Hight Up & Down






3 Setting Problem 6 In Process Inspection 4 72












Fitment Problem in Next Operation Setting Problem In Process Inspection 4 0


By OEM.Setting Problem / Die Wear In Process Inspection 4 0





















Punching Plate Side Hight Up & Down

Punching Bush Side Diameter Up & Down

Diameter Up & Down

Starightness ( 90⁰ )

Distance Up& Down

RA CONT. ROD. PIPE Ø19.10

Bending Length Up & Down

Pipe Cutting Length Up & Down

Radius cutting (bush side) Visual

Diameter Up & Down

RA U` BKT. CONT. ROD.



Bending Radious Up & Down

Hole Piercing Fixture

Hight Up & Down

Starightness (90Π) Fixture

01 Hole Piercing Fixture

Appereance

Chamfer up&Down

RA LEVER ROD.

Shaft Cutting Length Up & Down

Turning Distance Up& Down

Radius Distance Up& Down

Hight Up & Down

Grinding Distance Up& Down

Hight Up & Down

Threading Distance Up& Down

Appereance

Appereance

Machining Length Up & Down

Shaft cutting Length Up & Down

Chamfering Both Side Visual

Diameter Up & Down

Machining Fixture

RA LEVER BUSH.

Shaft cutting Fixture

Appereance

Chamfering Both Side up&Down

5 Setting Problem 3 In Process Inspection 2 30






















By OEM.3 Setting Problem / Tool Wear / Miss Handling 2 In Process Inspection 5 30



By OEM.2 Setting Problem 5 In Process Inspection 4 40

Appereance Problem 3 Setting Problem 5 In Process Inspection 4 60













Diameter Up & Down

RA EXT. ROD. BUSH. 25.4


Dimension Up& Down

Machining Diameter Up & Down

C1

Length Up & Down

Dimension Up& Down

Chamfering Both Side Radious

Diameter Up & Down



Chamfering Visual

Diameter Up & Down

RA SPACER BUSH.


Diameter Up & Down


Drilling Visual

Radious

Dimension Up& Down

Chamfering Both Side Taper Up & Down

Appereance

Appereance

Galvanizing Dimension Up& Down

Ball Welding 1st Side Distance Up& Down

RA LEVER WELDING.

Bush Welding Visual

Ball Welding 2nd Side Appereance

Hight Up & Down

Bending Length Up & Down

RA PIPE 19.1 ASSY (WELDING)

Touch Welding (U` Bkt. & Bush) Appereance

Final Welding U` Bkt. Appereance

Paint Over Flow & Pain Miss


Final Welding Bush Appereance

RA EXT. ROD. WELDING (PIPE 25.4)














By OEM.Setting Problem / Tool Wear / Miss Handling In Process Inspection 4 0

Rust Parts , Damage Parts 6 Unproper 2 In Process Inspection 1 12

Demaged parts not accepted by

OEM6 Unproper 1 10 60


OEM5 Improper stacking on vahicle not filt, Rash driving 5 Stacjing , Instruction , Inspection 4 ##



Chamfering Both Side

Packing

Storage

Dimension Up& Down

Appereance

Material

Delivery

Touch Welding (Ext, Plate & Bush) Appereance

Final Welding (Ext, Plate & Bush) Appereance

RA BUSH RUBBER EXT. ROD.



Diameter Up & Down


Radious

Drilling Visual

Taper Up & Down

O

C

D

E

R

P

FMEA Number ___14_______________________

Prepared By ___Zaffar Razzaq_______________________

POTENTIAL


(PROCESS FMEA)

Date (Orig) ___08-01-2008_________________________

Date (Rev) __________________________

Action Results

Team ______Develoment, Production, QC______________________________________________________________________________________________

S

E

V

O

C

R

Fitment In Next Operation 6 3 4 72









Fitment In Next Operation 2 0























POTENTIAL


(PROCESS FMEA)

Date (Orig) __10-01-2008__________________

Date (Rev) _____________________________

Part Name/ Item__ROD. COMP. REAR TRAILLING L , R Doc # ___QC\FM\009_________________________ FMEA Number __11________________________

Part # __________46210-54G10 , 46210-54G20___________________ Process Responsibility___Production and QC_______ Prepared By ___Zaffar Razzaq______________

Process Function / Requirements Potential Failure Mode Potential Effect(s) of Failure

S

E

V

OEM _________Pak Suzuki__________________________________

R P NRecommended

Actions

Responsibility &

Target Date

C

L

A

S

S


O

C

C

U

R

Current Process Controls

Action Results

Action Taken

Pipe Dia 25.4

D

E

T

E

Diameter Up &Down Setting Problem In Process inspection

Cutting LengthUp & Down

Bending Bending Marks Setting Problem In Process inspection

Setting Problem In Process inspection

Height after Bending Setting Problem In Process inspection

Length After Nib Cutting Setting Problem In Process inspection

Nib Cutting Height after Bending

Radius Cutting Radius Depth Setting Problem In Process inspection


Radius Setting Problem In Process inspection

Shearing 01 Length Up & Down Setting Problem In Process inspection

Sub Bracket

Thickness up&Down In Process inspection

Width Up&down Setting Problem In Process inspection

Bending Length Up & Down Setting Problem In Process inspection

Blanking Width Up&down

Hight Up & Down Setting Problem In Process inspection


Piericing Φ7 Diameter Up & Down Setting Problem In Process inspection

Nut Spot M6 Visual Setting Problem In Process inspection

Distance Up& Down

Size Up & Down Setting Problem In Process inspection


Hit Setting Problem In Process inspection

Bush Ø 51

Nut Welding Visual

Shaft Cutting Length Up & Down Setting Problem In Process inspection


CNC Machining Length Up & Down Setting Problem In Process inspection

Chamfer Up & Down Setting Problem In Process inspection

Diameter Up & Down

Chamfering Chamfer Up & Down Setting Problem In Process inspection


U Bracket

Thickness up&Down In Process inspection


Width Up&down Setting Problem In Process inspection


Blanking Length Up & Down Setting Problem In Process inspection

Bending Dimension Up & Down Setting Problem In Process inspection

Width Up&down

Height Up & Down Setting Problem In Process inspection














By OEM.4 3 3 36

Fitment not ok in vehical6 3 1 18

Rust Parts , Damage Parts 6 2 1 12


OEM6 1 10 60


OEM5 5 4 100



Delivery Improper stacking on vahicle not filt, Rash driving Stacjing , Instruction , Inspection

Storage Unproper

Ø12.8 Piercing Diameter Up & Down Setting Problem In Process inspection

Hit Setting Problem In Process inspection

Nut Spot M12 Visual Setting Problem In Process inspection

M 12 Nut Welding Visual Setting Problem In Process inspection

U BKT & Bush Stacking Fitment Setting Problem In Process inspection

U BKT & Bush WELDING

U BKT & Bush Final Welding Visual Setting Problem In Process inspection

Visual Setting Problem In Process inspection

U BKT & Bush Final Welding Fitment

Sub BKT Welding Fitment Setting Problem In Process inspection


Appereance Setting Problem In Process inspection


Taping Bolt Setting Problem In Process inspection

Final Inspection Dent Seprator In Process Inspection

Paint Operation Miss

Packing Material Unproper In Process Inspection

D

E

T

R

P

N

POTENTIAL


(PROCESS FMEA)

Date (Orig) __10-01-2008__________________

Date (Rev) _____________________________

FMEA Number __11________________________

Prepared By ___Zaffar Razzaq______________

Action Results

Action TakenS

E

O

C

D

E

BASE PLATE

Shearing 01 Length Up& Down problem in Next Operation 2 Seeting Problem 2 In Process Inspection 3 12

Width up& Down problem in Next Operation 2 Seeting Problem 3 In Process Inspection 3 18

Thickness Variation problem in Next Operation In Coming Inspection 0

Shearing 02 Length Up& Down problem in Next Operation 3 Setting Problem 4 In Process Inspection 3 36

Width up& Down problem in Next Operation 3 Setting Problem 4 In Process Inspection 4 48

Thickness Variation problem in Next Operation In Process Inspection 0

Notching 01 Distance Up& Down Problem in Next Operation 5 Setting Problem 4 In Process Inspection 2 40

Notching 02 Height Up & Down Problem in Next Operation 5 Setting Problem 3 In Process Inspection 2 30

Notching 03 Distance Up& Down Problem in Next Operation 5 Setting Problem 4 In Process Inspection 5 100

Height Up & Down Problem in Next Operation 5 Setting Problem 5 In Process Inspection 2 50

Distance Up& Down Problem in Next Operation 6 Setting Problem 6 In Process Inspection 3 108

Vertical Bush Welding Distance Up& Down Problem in Next Operation 4 Setting Problem 2 In Process Inspection 3 24

Diameter Up & Down Fitment Problem in next Operation 6 Punch Oroblem 3 In Process Inspection 2 36

Distance Up& Down Fitment Problem in next Operation 6 Setting Problem 2 In Process Inspection 3 36





Spot Nut M8 Spot Breack Fitment Problem in next Operation 4 Setting Problem 7 In Process Inspection 3 84

Spot Bkts Distance Up& Down Fitment Problem in next Operation 6 Guage Problem/Setting Problem 6 In Process Inspection 3 108

Final Welding Bkts Boring Diameter up Fitment Problem in next Operation 6 Setting Problem 3 In Process Inspection 3 54


Visual Fitment Problem in next Operation 4 Setting Problem 3 In Process Inspection 3 36





Galanizing Visual Appereancs Problem 6 Setting Problem 3 In Process Inspection 4 72

Doc # _____QC\FM\009__________________

OEM _________ Pak Suzuki____________________ Date (Orig) ___08-01-2008_______________

Team __ Develoment, Production, QC__________ Date (Rev) ___________________________

FMEA Number ___15_______________________

Part # __________28109-79505__________________ Prepared By ___Zaffar Razzaq_______________________Process Responsibility___Production and QC__

Part Name/ Item__STG GSL (BOLAN)_____________

O

C

C

U

Current Process

ControlsProcess Function / Requirements Potential Failure Mode Potential Effect(s) of Failure

S

E

V

Action Results

Bending

4 Hole Piercing

Dia 5 Hole Piercing

D

E

T

E

R

P

N


& Target Date

C

L

A

S


Bkt D Welding

POTENTIAL


(PROCESS FMEA)

Dia 9 Hole Piercing

Horizantal Bush 1st Welding

Horizantal Bush 2nd Welding

Thickness Variation Problem in Next Operation 6 Setting Problem 2 In Process Inspection 4 48

Setting Problem In Process Inspection 32

Setting Problem In Process Inspection 0

Length Up& Down Problem in Next Operation 5 Setting Problem 3 In Process Inspection 6 90

Distance Up& Down Problem in Next Operation 8 Setting Problem 3 In Process Inspection 4 96

Thickness Variation Problem in Next Operation 5 Setting Problem 3 In Process Inspection 5 75

Bending Height Up & Down Problem in Next Operation 4 Setting Problem 5 In Process Inspection 3 60

Diameter Up & Down Fitment Problem in next Operation 7 Setting Problem 6 In Process Inspection 2 84


Hole Piercing Dia 9 Diameter Up & Down Fitment Problem in next Operation 5 Setting Problem 3 In Process Inspection 3 45

90⁰ Fitment Problem in next Operation 6 Setting Problem 3 In Process Inspection 2 36


Nut Spot M8 Spot Breack Fitment Problem in next Operation 9 Setting Problem 3 In Process Inspection 4 108


Spot Breack Fitment Problem in next Operation 7 Setting Problem 3 In Process Inspection 6 126


Thickness Variation Problem In Next Operation 7 In Process Inspection 0

Problem In Next Operation 9 Setting Problem 1 In Process Inspection 4 36


Length Up& Down Problem In Next Operation 6 Setting Problem 4 In Process Inspection 2 48

Distance Up& Down Problem In Next Operation 8 Setting Problem 2 In Process Inspection 4 64


Bending Height Up & Down Fitment Problem in next Operation 4 Setting Problem 6 In Process Inspection 3 72



90⁰ Fitment Problem in next Operation 8 Setting Problem 3 In Process Inspection 2 48











Straihtness

Spot Washer + Horizontal Bush

STG Bracket A

Shearing Width up& Down Problem in Next Operation 4 4 2

Blanking

Hole Piercing 27.2

Blanking

Hole Piercing

Straihtness

STG Bracket C

STG Bracket B

Shearing Width up& Down


Blanking

Hole Piercing








Thickness Variation Problem In Next Operation In Process Inspection 0




Hole Piercing Dia 12 Diameter Up & Down Fitment Problem in next Operation 8 Setting Problem 3 In Process Inspection 2 48

Nut Spot M8 Spot Breack Fitment Problem in next Operation 7 Setting Problem 3 In Process Inspection 2 42

Nut M8 Welding Visual Fitment Problem in next Operation 6 Setting Problem 4 In Process Inspection 2 48

Treading Pin Welding Visual Fitment Problem in next Operation 4 Setting Problem 4 In Process Inspection 3 48

Thickness Variation Problem In Next Operation 7 4 In Process Inspection 4 112








Chamfering Visual Fitment Problem in next Operation 4 Setting Problem 3 In Process Inspection 6 72


Fixture Fitment Problem in next Operation 6 Setting Problem 1 In Process Inspection 2 12

Galvanizing Visual Appereanes Problem 3 Setting Problem 2 In Process Inspection 2 12





Notching Distance Up& Down Problem In Next Operation 8 Setting Problem 5 In Process Inspection 2 80

Diameter Up & Down Problem In Next Operation 6 Setting Problem 6 In Process Inspection 3 108




Flaring

STG Bracket D


Blanking

Hole Piercing

Bush Weld

STG Control Shaft

Blanking

Hole Piercing Dia 9

STG Gear Select Arm



2 Hole Piercing + Notching

1 Hole Piercing



Height Up & Down Fitment Problem in next Operation 6 Setting Problem 2 In Process Inspection 4 48


Final Bending Distance Up& Down Fitment Problem in next Operation 8 Setting Problem 2 In Process Inspection 3 48

Length Up& Down Fitment Problem in next Operation 4 Setting Problem 5 In Process Inspection 2 40








Pressing Distance Up& Down Fitment Problem in next Operation 6 Setting Problem 2 In Process Inspection 5 60






Galvanizing Visual Fitment Problem in next Operation 4 Setting Problem 1 In Process Inspection 7 28

Pre Drilling Diameter Up & Down Fitment Problem in next Operation 4 Setting Problem 4 In Process Inspection 2 32

Ø22 Boring Diameter Up & Down Fitment Problem in next Operation 5 Setting Problem 2 In Process Inspection 3 30

Ø16 Boring Diameter Up & Down Fitment Problem in next Operation 6 Setting Problem 2 In Process Inspection 4 48

Ø6 Drilling Diameter Up & Down Fitment Problem in next Operation 7 Setting Problem 3 In Process Inspection 5 105

Ø8 Drilling Diameter Up & Down Fitment Problem in next Operation 2 Setting Problem 3 In Process Inspection 6 36


Shaft Cutting Length Up& Down No Problem


Inner Dia Fitment Problem in next Operation 5 Setting Problem 3 In Process Inspection 4 60

Outer Dia Fitment Problem in next Operation 6 Setting Problem 4 In Process Inspection 4 96


Shaft Cutting Length Up& Down No Problem In Process Inspection



Bending 5mm

STG Guide Shaft

Shaft Cutting

Facing

1 Hole Piercing

Ø6 Hole Drilling

STG Yoke

STG Horizantal Bush

Machining

Grinding

STG Guide Shaft & Arm Welding

Arm Welding 1&2

Ø5 2Hole Drilling

STG Threaded Pin

Machining

Dimension Up & Down Fitment Problem in next Operation 7 Setting Problem 5 In Process Inspection 3 105

Threading Fitment Problem in next Operation 6 Setting Problem 3 In Process Inspection 6 108


Shaft Cutting Length Up& Down No Problem





Shaft Cutting Length Up& Down Fitment Problem in next Operation 4 Setting Problem 2 In Process Inspection 2 16



Height Up & Down Fitment Problem in next Operation 3 Setting Problem 4 In Process Inspection 6 72



STG Dia 6 Pin

Drilling Diameter Up & Down Fitment Problem in next Operation 4 Setting Problem 2 In Process Inspection 2 16



Galvanizing Visual Fitment Problem in next Operation 2 Setting Problem 2 In Process Inspection 3 12

STG Dia 8 Pin

Drilling Diameter Up & Down Fitment Problem in next Operation 8 Setting Problem 3 In Process Inspection 3 72



Galvanizing Visual Appereance Problem 2 Setting Problem 3 In Process Inspection 4 24

Packing Material Rust Parts , Damage Parts 6 Unproper 2 In Process Inspection 1 12

StorageDemaged parts not accepted by

OEM6 Unproper 1 10 60

DeliveryDemaged parts not accepted by

OEM5 Improper stacking on vahicle not filt, Rash driving 5


Inspection4 100



Machining

STG Vertical Bush Bush

Machining

Machining

Threading

STG Select Arm Bush

R

P

Action Results

POTENTIAL


(PROCESS FMEA)

STG Bracket A

STG Bracket C

STG Bracket B

STG Bracket D

STG Control Shaft

STG Gear Select Arm

STG Guide Shaft

STG Yoke

STG Horizantal Bush

STG Guide Shaft & Arm Welding

STG Threaded Pin

STG Vertical Bush Bush

STG Select Arm Bush

Action TakenS

E

Problem in Next

Operation3 Setting Problem 3 In Process Inspection 3 27

Problem in Next

Operation3 4 In Process Inspection 3 36

Problem in Next


Problem in Next


Problem in Next


Problem in Next








Appereance Problum

not accepted By OEM.4 5 In Process Inspection 3 60


Appereance Problum

not accepted By OEM.4 Setting Problem 5 In Process Inspection 3 60



Appereance Problum




Piercing

6 Hole Peiricing

Shearing 02

Φ10 Hole piericing

POTENTIAL


(PROCESS FMEA)

Shearing 01

Forming

Blanking

FMEA Number ___10_______________________Part Name/ Item__SF GSL310___________

Process Responsibility___Production and QC__________________ Prepared By ___Zaffar Razzaq______________

Date (Orig) ___08-01-2008_________________

Doc # ____QC\FM\009_____________________________

R

P

N

Recommended

Actions

Date (Rev) __________________________C

L

A

S

Potential Cause(s) /

Mechanism(s) of Failure

O

C

C

U

Current Process

Controls

Action ResultsD

E

T

E

Responsibility & Target

Date

BASE PLATE

Length Up & Down

Process Function /

RequirementsPotential Failure Mode Potential Effect(s) of Failure

S

E

V

Thickness up&Down

Width Up&down

Length Up & Down

Thickness up&Down

Width Up&down

Width Up&down

Distance Up& Down

Diameter Up& Down

Distance Up& Down

Appearance

Length Up & Down

Width Up&down

Appearance

Diameter Up& Down

Distance Up& Down

Appearance

Distance Up& Down

Spot Nut M6 Hit

SpotHook Spot

Part # ____28100 - 60 E 50______________

OEM ____Pak Suzuki_______________________________

Team _Develoment, Production, QC_____________________________________________________________________________________________

Appereance Problum


Appereance Problum


Problem in Next Operation 3 Setting Problem 3 In Process Inspection 3 27







Problem in Next Operation Setting Problem In Process Inspection 0


Problem in Next Operation 3 4 In Process Inspection 3 36









Appereance Problum



Appereance Problum







M6 Nut Welding Visual

Galvonizing Visual

SF BUSH



Diameter Up& Down

SF BALL

Distance Up& Down

Chamfering Visual



Diameter Up& Down

Hight Up & Down

Diameter Up& Down

Thickness up&Down

Forming Distance Up& Down

SF COVER BOOT

4 Hole Peiricing

Chamfering Visual


Width Up&down

Thickness up&Down

Blanking Length Up & Down

Width Up&down

Appearance

Strightness Straightness

SF HOOK

Galvonizing Visual


Width Up&down

Thickness up&Down

Hole Peiricing Diameter Up& Down

Shearing Dimention up& Down







Appereance Problum

















Appereance Problum not

accepted By OEM.4 Setting Problem 5 In Process Inspection 3 60


Demaged parts not

accepted by OEM6 Unproper 1 10 60

Demaged parts not

accepted by OEM5

Improper stacking on

vahicle not filt, Rash

driving

5Stacjing , Instruction ,

Inspection4 100


Delivery

Hight Up & Down

Distance Up& Down

Flaring Diameter Up& Down

SF LEVER

WELDING

Blanking Dimenstion up& Down

Dimenstion up& Down

Hight Up & Down

Bending Diameter Up& Down

Appearance

Diameter Up& Down

Diameter Up& Down

Turning


Dimenstion up& Down

Radius

Grinding Diameter Up& Down

Radius up&Down

Threading Threading

Bush Welding Taper Up& Down

Storage

Bending Dimenstion up& Down

Dimenstion up& Down

Ball Welding 1st Side Dimenstion up& Down


Appereance

Hight Up & Down

Paint Thickness up&Down

Packing Material

Majid Mehmood (Manager Q.C)Mr. Rafi (Manager

Production)

Zaffar Razzaq (Asst.

Manager Q.C)

O

C

D

E

R

P

POTENTIAL


(PROCESS FMEA)

FMEA Number ___10_______________________


Date (Orig) ___08-01-2008_________________

Date (Rev) __________________________

Action Results

Action TakenS

E

Problem in Next


Problem in Next


Problem in Next


Problem in Next


Problem in Next


Problem in Next








Appereance Problum



Appereance Problum




Appereance Problum




Part # ____28100-60E50______________

OEM ____Pak Suzuki_______________________________

Team _Develoment, Production, QC_____________________________________________________________________________________________

Spot Nut M10

Spot Nut M6 Hit

Spot

Appearance

Distance Up& Down

Diameter Up& Down

Distance Up& Down

Appearance

Appearance

Length Up & Down

Distance Up& Down

Width Up&down

Thickness up&Down

Width Up&down

Width Up&down

Distance Up& Down

Length Up & Down

Diameter Up& Down

Thickness up&Down

Width Up&down


Date

BASE PLATE

Length Up & Down

Process Function /


S

E

V

R

P

N

Recommended

Actions

Date (Rev) __________________________C

L

A

S

Potential Cause(s) /

Mechanism(s) of Failure

O

C

C

U

Current Process

Controls

Action ResultsD

E

T

E

Process Responsibility___Production and QC__________________ Prepared By ___Zaffar Razzaq______________

Date (Orig) ___10-01-2008_________________

Doc # ____QC\FM\009_____________________________

POTENTIAL


(PROCESS FMEA)

FMEA Number ___16_______________________Part Name/ Item__SB GSL308___________

Shearing 01

Forming

Blanking

Bending

6 Hole Peiricing

Shearing 02

Piericing

Appereance Problum


Appereance Problum




















Appereance Problum



Appereance Problum






Problem in Next Operation 3 Setting Problem 4 In Process Inspection 4 48Radius Diameter Up& Down

Thickness up&Down

Turning Dimention up& Down

Width Up&down

Galvonizing Visual


Appearance

Straightness


Width Up&down

Strightness

SB LEVER

Thickness up&Down


Width Up&down

SB COVER BOOT

4 Hole Peiricing

Chamfering Visual

Diameter Up& Down

Hight Up & Down

Diameter Up& Down

Thickness up&Down

Forming Distance Up& Down



SB BALL

Distance Up& Down

Chamfering Visual


Diameter Up& Down


SB BUSH

Galvonizing Visual

M6 Nut Welding Visual







Appereance Problum









Appereance Problum



Demaged parts not


Demaged parts not

accepted by OEM5



driving


Inspection4 100


Packing Material

Hight Up & Down

Dimenstion up& Down


Appereance

Dimenstion up& Down

Dimenstion up& Down

Ball Welding 1st Side

Bush Welding Taper Up& Down

Storage

Bending

Dimenstion up& Down

Hight Up & Down

Appearance

Hight Up & Down

Distance Up& Down

Grinding Diameter Up& Down

BUSH & BALL WELDING

Threading Diameter Up& Down

Approved By:

Mr. Rafi (Manager

Production)

Delivery


Manager Q.C)

Prepared By: Approved By:

Majid Mehmood (Manager Q.C)

O

C

D

E

R

P

Date (Rev) __________________________

Action Results


Date (Orig) ___10-01-2008_________________

POTENTIAL


(PROCESS FMEA)

FMEA Number ___16_______________________

Action TakenS

E

O

C

D

E

R

P

Problem in Next


Problem in Next


Problem in Next


Problem in Next


Problem in Next


Problem in Next


















Center Drilling

Deburring

Team _ Develoment, Production, QC__________________

Cutting

Width Up&down

Diameter Up& Down

Date (Orig) ___07-01-2008_________________

Doc # ___QC\FM\009____________________

POTENTIAL


(PROCESS FMEA)

FMEA Number ___02_______________________

Prepared By ___Zaffar Razzaq______________Process Responsibility___Production and QC_

Part Name/ Item__SHAFT ASSEMBLY PROPELLER (STP-308)___

Part # ____ 27100-79072___________________________

OEM ____ Pak Suzuki_______________________________

Chamfering

PIPE

Date (Rev) __________________________C

L

A

S

Potential Cause(s) / Mechanism(s)

of Failure

O

C

C

U

Current Process

Controls

Action ResultsD

E

T

E


Date

Length Up & Down

Process Function /


S

E

V

R

P

N

Recommended

Actions

Thickness up&Down

Length Up & Down

Boring

TUBE YOKE

Length Up & Down

Thickness up&Down

Width Up&down

Length Up & Down

Diameter Up& Down

Turning Length Up & Down

Length Up & Down

Diameter Up& Down

Leg Facing Length Up & Down

Boring

FLANGE YOKE

Length Up & Down

Turning Length Up & Down

Pre Drilling Visual

Diameter Up& Down

Leg Facing Visual

Width Up&down

Deburring Length Up & Down

Thickness up&Down
























Appereance Problum


Rust Parts , Damage

Parts6 Unproper 2 In Process Inspection 1 12

Demaged parts not


Demaged parts not

accepted by OEM5



driving


Inspection4 100


Approved By:

Mr. Rafi (Manager

Production)

Delivery


Manager Q.C)


Counter Distance Up& Down

Width Up&down

Drilling Length Up & Down

Thickness up&Down

WEIGHT

Hight Up & Down

Thickness up&Down


Width Up&down

Blanking Dimention up& Down

STP SHAFT ASSEMBLY

Dimenstion up& Down

Diameter Up& Down

Diameter Up& Down

Bearing Fitting YCJF

Welding

Yoke Pressing Length Up & Down

Dimenstion up& Down

Radius up&Down

Distance Up& Down

Bending & Notching Diameter Up& Down

Calking YCS Threading

Bearing Fitting YCS Diameter Up& Down

Storage

Dimenstion up& Down

Balancing Dimenstion up& Down

Calking YCJF Taper Up& Down

Appereance


Packing Material

Action TakenS

E

O

C

D

E

R

P

Problem in Next


Problem in Next


Problem in Next


Problem in Next


Problem in Next


Problem in Next








Appereance Problum



Appereance Problum




Appereance Problum




Appereance Problum


TUBE YOKE

FLANGE YOKE

Pre drilling

Boaring Visual

Turning Hit

Spot

Appearance

Distance Up& Down

Diameter Up& Down

Distance Up& Down

Appearance

Appearance

Length Up & Down

Width Up&down

Width Up&down

Distance Up& Down

Thickness up&Down

Width Up&down

Distance Up& Down

Length Up & Down

Diameter Up& Down

Thickness up&Down

Width Up&down


Date

PIPE ASSY.

Length Up & Down

Process Function /


S

E

V

R

P

N

Team _ Develoment, Production, QC__________________

Recommended

Actions

Date (Rev) ____________________________C

L

A

S

Potential Cause(s) / Mechanism(s)

of Failure

O

C

C

U

Current Process

Controls

Action ResultsD

E

T

E

Date (Orig) ___02-01-2008________________

Doc # ___QC\FM\009____________________

Process Responsibility___Production and QC_

Part Name/ Item__SHAFT ASSEMBLY PROPELLER (SHP)___

Part # ____ 27100-77105___________________________

OEM ____ Dewan Farooq_______________________________

POTENTIAL


(PROCESS FMEA)

FMEA Number ___01_______________________

Prepared By ___Zaffar Razzaq_____________

Cutting

Pre drilling

Boaring

Center Drilling

Deburing

Chamfering

Turning

Appereance Problum


Appereance Problum


Appereance Problum




















Appereance Problum


Appereance Problum


Rust Parts , Damage

Parts6 Unproper 2 In Process Inspection 1 12

Demaged parts not


Demaged parts not

accepted by OEM5



driving


Inspection4 100

Counter Visual

Drilling


Packing Material

Storage

Visual

Hight Up & Down

Width Up&down

Bearing Fitting YCS Length Up & Down

Width Up&down

Thickness up&Down

Circlip YCJF Length Up & Down

Balancing Diameter Up& Down

Appearance

Diameter Up& Down

Thickness up&Down

Circlip YCS Distance Up& Down

Bearing Fitting YCJF Visual

Yoke Pressing Length Up & Down

Welding Length Up & Down

PROPELLER SHAFT ASSY.

Distance Up& Down

Bending & Notching Visual


Diameter Up& Down

WEIGHT


Deburing Visual

Approved By:

Mr. Rafi (Manager

Production)

Delivery


Manager Q.C)



copy of copy of potential (fmea) (original)

Documents