FMEA-Extrusion-error Proofing [PDF]

Zitiervorschau

Document F/NPD/06-Ext

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PFMEA) : Automotive Inner Butyl Tube

Process

: Extrusion of Green Tube ……. Process-04

Customer

: All Customer

Process Responsibility

: Technical / QA

Process Owner

: Production Head

Potential Effects(s) of Failure

Buckle

(A Portion of the production run may have to be scrapped. Deviation from primary process including decreased line speed or added man power)

2

1-Extrusion as per F/QAD/24 2-Setup as per W-PRD-23 2-Work execution as per F/PRD/04SOP:02 & W-PRD-08

1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 .

5 ###

7

Incorrect Dimensions of Feed

2

1-Extrusion as per F/QAD/24 2-Work execution as per F/PRD/04SOP:02 & W-PRD-08

1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 .

5 ###

2

1-Mixing of Work away as per WPRD/10 2-Work execution as per F/PRD/04SOP:02 & W-PRD-08

1-Visual by Operator 2-One Check / Day by QA Supervisor as per F/QAD/11 .

5 ###

2

1-Extrusion as per F/QAD/24 2-Work execution as per F/PRD/04SOP:02 & W-PRD-08 3-Line Speed data analysed and Spec displayed

2

1-Extrusion as per F/QAD/24 2-Setup as per W-PRD-23 2-Work execution as per F/PRD/04SOP:02 & W-PRD-08

2

1-Extrusion as per F/QAD/24 2-Work execution as per F/PRD/04SOP:02 & W-PRD-08

7

7

Thin Side

Tube Perimeter , Tube Gauge , Extruded Tube Temp , 4.1 / Uniform Inner Extrusion of Dusting , Tube Line identification on Tube - As per Spec .

(A Portion of the production run may have to be reworked offline and accepted)

-

Screw RPM variation

Wrong Size Setup

Incorrect Dimensions of Feed

7

Excess Quantity of Work away

Screw RPM variation

5

Wrong Size Setup

5

Incorrect Dimensions of Feed

5

Excess Quantity of Work away

2

2

2

2

1-Extrusion as per F/QAD/24 2-Work execution as per F/PRD/04SOP:02 & W-PRD-08

2

1-Mixing of Work away as per WPRD/10 2-Work execution as per F/PRD/04SOP:02 & W-PRD-08

Screw RPM variation

2

7

Line Speed - Out of Spec .

2

Wrong Size Setup

2

2

1-Extrusion as per F/QAD/24 2-Work execution as per F/PRD/04SOP:02 & W-PRD-08

Incorrect Dimensions of Feed

5

Excess Quantity of Work away

2

5

Screw RPM variation

2

7

Line Speed - Out of Spec .

2

-

Loss of Primary Custom function 8 er End (Vechile inoperable,does not

1-Extrusion as per F/QAD/24 2-Work execution as per F/PRD/04SOP:02 & W-PRD-08 3-Line Speed data analysed and Spec displayed 1-Extrusion as per F/QAD/24 2-Work execution as per F/PRD/04SOP:02 & W-PRD-08 3-Line Speed data analysed and Spec displayed 1-Extrusion as per F/QAD/24 2-Setup as per W-PRD-23 2-Work execution as per F/PRD/04SOP:02 & W-PRD-08

5

3

1-Mixing of Work away as per WPRD/10 2-Work execution as per F/PRD/04SOP:02 & W-PRD-08 1-Extrusion as per F/QAD/24 2-Work execution as per F/PRD/04SOP:02 & W-PRD-08 3-Line Speed data analysed and Spec displayed 1-Extrusion as per F/QAD/24 2-Setup as per W-PRD-23 2-Work execution as per F/PRD/04SOP:02 & W-PRD-08

5

5

Pinch Mould

Excess Quantity of Work away

7

7

(A Portion of the production run may have to be reworked offline and accepted)

3

1-Mixing of Work away as per WPRD/10 2-Work execution as per F/PRD/04SOP:02 & W-PRD-08 1-Extrusion as per F/QAD/24 2-Work execution as per F/PRD/04SOP:02 & W-PRD-08 3-Line Speed data analysed and Spec displayed 1-Extrusion as per F/QAD/24 2-Work execution as per F/PRD/04SOP:02 & W-PRD-08 3-Line Speed data analysed and Spec displayed

-

Tube Guage Out of Spec .

Custom er End

Weight Variation

(A Portion of the production run may have to be reworked offline and accepted)

Degradation of secondary function

3

Wrong Size Setup

2

3

Incorrect Dimensions of Feed

2

1-Extrusion as per F/QAD/24 2-Work execution as per F/PRD/04SOP:02 & W-PRD-08

3

Screw RPM variation

2

7

Line Speed - Out of Spec .

2

(Vechile operable,but Cofort/convenience functions at reduced level of performance)

5

(A Portion of the production run may have to be reworked offline accepted) Weakand / Open Splice

Cured Lump in Tubes

(A Portion of the production run may have to be scrapped.Deviation from primary process including

(A Portion of the production run may have to be reworked offline and accepted)

Custom er End

NIL

-

3

1-Extrusion as per F/QAD/24 2-Work execution as per F/PRD/04SOP:02 & W-PRD-08 3-Line Speed data analysed and Spec displayed 1-Extrusion as per F/QAD/24 2-Work execution as per F/PRD/04SOP:02 & W-PRD-08 3-Line Speed data analysed and Spec displayed

-

1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 . 1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 . 1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 . 1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 . 1-Visual by Operator 2-One Check / Day by QA Supervisor as per F/QAD/11 . 1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 . 1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 .

Daily QA Check Sheet (PFM)

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1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 . 1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 . 1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 . 1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 .

Daily QA Check Sheet (PFM)

### 5 ### 5 ### 5

5 ### 3 ###

Daily QA Check Sheet (PFM)

5 ###

-

-

Temp.of Circulating Water in Head - Out of Spec

2

1-Extrusion as per F/QAD/24 2-Work execution as per F/PRD/04SOP:02 & W-PRD-08

Temp.of Circulating Water in Head - Out of Spec

3

1-Extrusion as per F/QAD/24 2-Work execution as per F/PRD/04SOP:02 & W-PRD-08

Temp.of Circulating Water in Head - Out of Spec

3

1-Extrusion as per F/QAD/24 2-Work execution as per F/PRD/04SOP:02 & W-PRD-08

3

5 ###

-

7

-

5 ###

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3

-

5 ###

5 ###

3

3

1-Visual by Operator 2-One Check / Day by QA Supervisor as per F/QAD/11 .

5 ###

1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 . 1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 . 1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 . 1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 .

1-Extrusion as per F/QAD/24 2-Work execution as per F/PRD/04SOP:02 & W-PRD-08

3

1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 . 1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 . 1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 .

3 Temp.of Circulating Water in Head - Out of Spec

(Next decreased line speed or Extruded added man power) Process Pinch Splice Tube (A Portion of the production ) 3 Temp. may have to be reworked Our End run offline and accepted) Out of Spec . Valve Pinch

1-Visual by Operator 2-One Check / Day by QA Supervisor as per F/QAD/11 .

Page

1OF 3

& Target Action Results Action SDOR

Action(s)

3 ### 1-Extrusion as per F/QAD/24 2-Setup as per W-PRD-23 2-Work execution as per F/PRD/04SOP:02 & W-PRD-08

3

1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 . 1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 . 1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 .

2

affect safe vechile operation)

(Next Process ) Our End

Current Process Control (Detection)

Wrong Size Setup

Crack Splice

(Next Process Tube ) Perimeter Our End - Out of Spec.

Recomm ended Current Process Control (Prevention)

06

Revision D22.04.2021

7

7

(A Portion of the production run may have to be scrapped. Deviation from primary process including decreased line speed or added man power)

Potential cause(s) Mechanism(s) of Failures

Revision Respons No. ibility

DETECT RPN

Potential Failure Requirement Mode

OCCUR

Sub Process Step/ Function

SEV CLASS

Product

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Completi on

Document F/NPD/06-Ext

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PFMEA) : Automotive Inner Butyl Tube

Process

: Extrusion of Green Tube ……. Process-04

Customer

: All Customer

Process Responsibility

: Technical / QA

Process Owner

: Production Head

Potential Failure Mode

Potential Effects(s) of Failure

Pinch Splice

(A Portion of the production run may have to be reworked offline and accepted)

Tube Perimeter , Tube Gauge , Extruded 4.1 / Tube Temp , Extrusion of Uniform Inner Tube Dusting , ( Continued Line …) identification on Tube - As per Spec .

(Next Process ) Our End

W/O Splice

(A Portion of the production run may have to be reworked offline and accepted)

Moisture in Dusting Powder

3

Pressure of Inner Dusting - Out of Spec .

3

3

3

Non Uniform Inner Dusting

Potential cause(s) Mechanism(s) of Failures

Custom er End

Customer Dissatisfaction

2

1-Air Filter / Heater / Vibrator provided 2-Plate Modified for Better Flow. 3-Extrusion as per F/QAD/24 . 4-Work execution as per F/PRD/04SOP:02 and W-PRD-08 & W-PRD-09 .

1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 .

Pressure of Inner Dusting - Out of Spec .

2

1-Air Filter / Heater / Vibrator provided 2-Plate Modified for Better Flow. 3-Extrusion as per F/QAD/24 . 4-Work execution as per F/PRD/04SOP:02 & W-PRD-08

1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 .

Cured Lump in Tubes

(A Portion of the production run may have to be reworked offline and accepted)

(Next W/O Splice Process (A Portion of the production 4.2 / Cooling Extruded Extruded ) run may have to be of Extruded Tube Cooled Tube Hot Our End scrapped.Deviation from Tube primary process including decreased line speed or added man power)

-

3

-

1 -

-

1

-

3 3 -

(A Portion of the production run may have to be reworked offline and accepted)

Custom er End

No effect Length Buckle

(A Portion of the production run may have to be scrapped.Deviation from primary process including decreased line speed or added man power)

(Next 4.3 / Auto Cut- Process ©Tube Length Extruded Length - ) Cut as per W / O Splice Tube Length Out of Our End (A Portion of the production Specification Cutting Spec run may have to be scrapped.Deviation from primary process including decreased line speed or added man power)

Custom er End

No effect Tube Under Cure

(A Portion of the production run may have to be scrapped.Deviation from primary process including decreased line speed or added man power)

Patch Applicatio 4.4 /Patch Patch n - Off Fixing on Application on center & Green Tube C/L and in& Size appropriate appropriat stamping Stamping . e Stamping .

(Next Under Cure Process Valve (A Portion of the production ) run may have to be Our End scrapped.Deviation from primary process including decreased line speed or added man power)

Stamping not clear Custom er End

No effect

Colouring Cylinder 2 Malfunctioning

-

3

-

2

1-Extrusion as per F/QAD/24 . 2-Work execution as per F/PRD/04SOP:02 & W-PRD-19

-

3

Temp.of Cooling Water on Conveyor - Out of Spec

3

1-Extrusion as per F/QAD/24 . 2-Work execution as per F/PRD/04SOP:02 & W-PRD-08

3

Line Speed - Out of Spec .

3

1-Extrusion as per F/QAD/24 . 2-Work execution as per F/PRD/04SOP:02 & W-PRD-08

7

Temp.of Cooling Water on Conveyor - Out of Spec

2

1-Extrusion as per F/QAD/24 . 2-Work execution as per F/PRD/04SOP:02 & W-PRD-08

7

Line Speed - Out of Spec .

2

1-Extrusion as per F/QAD/24 . 2-Work execution as per F/PRD/04SOP:02 & W-PRD-08

3

Moisture on Tube Surfaces

3 Job setup by Operator

Valve Blister

3

-

3

-

1 -

-

1

-

Setting of Length8 E Photo Sensor - Out of Spec

8

Line Speed - Out of Spec .

Setting of Length8 E Photo Cell - Out of Spec .

8

Line Speed - Out of Spec .

2

1-Extrusion as per F/QAD/24 . 2-Work executed as per F/PRD/04SOP:02 & W-PRD-08 .

2

1-Extrusion as per F/QAD/24 . 2-Work execution as per F/PRD/04SOP:02 & W-PRD-08

2

1-Extrusion as per F/QAD/24 . 2-Work executed as per F/PRD/04SOP:02 & W-PRD-08 .

2

1-Extrusion as per F/QAD/24 . 2-Work execution as per F/PRD/04SOP:02 & W-PRD-08

3

-

3

-

1 -

-

1

-

7

Patch Distance Out of Spec .

2

Patch Distance Out of Spec .

1-Extrusion as per F/QAD/24 . 2-Check as per W-PRD-08 (Patch Application) 1-Extrusion as per F/QAD/24 . 2-Check as per W-PRD-08 (Patch Application)

Patch Offcenter Out of Spec .

7

5 ###

Moisture in Dusting Powder

3

2

1-Extrusion as per F/QAD/24 . 2-Check as per W-PRD-08 (Patch Application)

1-Extrusion as per F/QAD/24 . 2-Check as per W-PRD-08 (Patch Application)

7

Patch Offcenter Out of Spec .

2

7

1-Stamping at Wrong Place 2-Hazy Stamping

2

3

-

3

1 -

-

1

Completi on

5 ###

1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 .

5 ###

5 ###

Daily QA Check Sheet (PFM) 1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 .

5 ###

5 ### 1 1

5 ###

Daily QA Check Sheet (PFM)

5 ###

-

5 ###

1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 . 1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 . 1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 .

5###

1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 .

5###

Visual /Extrusion Operator

5 ###

Daily QA Check Sheet (PFM) -

5 ###

1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 . 1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 . 1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 . 1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 .

Daily QA Check Sheet (PFM) -

1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 . 1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 . 1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 .

1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 . 1-Visual by Operator 1-Extrusion as per F/QAD/24 . 2-Every Size / Shift by 2-Check as per W-PRD-08 (Stamping Prod.Suprvisor as per F/PRD/12 ) 3-One Check / Day by QA Supervisor as per F/QAD/11 .

-

Daily QA Check Sheet (PFM)

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-

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1 1

2 OF 3

& Recomm Target Action Results ended Action(s) Action SDOR

5 ###

1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 .

2

7

7

1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 .

Pressure of Inner Dusting - Out of Spec .

7 Custom Curing & Down No effect er End stream processingOut of Spec . (A Portion of the production run may (Next have to be Process scrapped.Deviation Line from primary process identificati ) on-Out of Our End including decreased line speed or added Spec . man power)-

1-Air Filter / Heater / Vibrator provided 2-Plate Modified for Better Flow. 3-Extrusion as per F/QAD/24 . 4-Work execution as per F/PRD/04SOP:02 & W-PRD-08 1-Air Filter / Heater / Vibrator provided 2-Regulator & Nozzle-flow controlled inside-dusting. 3- Inner-dusting-pr is adjusted according the tube-size prior to extrusion 4-Plate Modified for Better Flow. 5-Extrusion as per F/QAD/24 . 6-Work execution as per F/PRD/04SOP:02 and W-PRD-08 & W-PRD-09 . 1-Air Filter / Heater / Vibrator provided 2-Plate Modified for Better Flow. 3-Extrusion as per F/QAD/24 . 4-Work execution as per F/PRD/04SOP:02 & W-PRD-08

1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 .

2

7

(A Portion of the production run may have to be reworked offline and accepted)

1-Air Filter / Heater / Vibrator provided 2-Plate Modified for Better Flow. 3-Extrusion as per F/QAD/24 . 4-Work execution as per F/PRD/04SOP:02 and W-PRD-08 & W-PRD-09 .

Current Process Control (Detection)

Moisture in Dusting Powder

7

Valve Blister

Current Process Control (Prevention)

06

Revision D22.04.2021

DETECT RPN

Requirement

Revision Respons No. ibility

Page OCCUR

Sub Process Step/ Function

SEV CLASS

Product

Document F/NPD/06-Ext

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PFMEA) : Automotive Inner Butyl Tube

Process

: Extrusion of Green Tube ……. Process-04

Customer

: All Customer

Process Responsibility

: Technical / QA

Core team

: RD/DKS/MB/SNS/PY/ASK

Process Owner

: Production Head

Potential Failure Mode

Potential Effects(s) of Failure

Pinch Splice

(A Portion of the production run may have to be reworked offline and accepted)

Potential cause(s) Mechanism(s) of Failures Wet Powder

3

1-Dry Talcam Powder used . 2-Work execution as per F/PRD/04SOP:02 and W-PRD-09

Untrained Operator

3

1-Dry Talcam Powder used . 2-Work execution as per F/PRD/04SOP:02 and W-PRD-09 3-Trained Operator deployed .

Wet Powder

3

1-Dry Talcam Powder used . 2-Work execution as per F/PRD/04SOP:02 and W-PRD-09

Untrained Operator

3

1-Dry Talcam Powder used . 2-Work execution as per F/PRD/04SOP:02 and W-PRD-09 3-Trained Operator deployed .

Wet Powder

3

1-Dry Talcam Powder used . 2-Work execution as per F/PRD/04SOP:02 and W-PRD-09

Untrained Operator

3

1-Dry Talcam Powder used . 2-Work execution as per F/PRD/04SOP:02 and W-PRD-09 3-Trained Operator deployed .

Wet Powder

3

1-Dry Talcam Powder used . 2-Work execution as per F/PRD/04SOP:02 and W-PRD-09

Untrained Operator

3

1-Dry Talcam Powder used . 2-Work execution as per F/PRD/04SOP:02 and W-PRD-09 3-Trained Operator deployed .

3

3 W/O Splice

(A Portion of the production run may have to be scrapped.Deviation from primary process including decreased line speed or added man power)

Nonuniform Outer Dusting

(Next Process ) Our End Valve Blister

(A Portion of the production run may have to be reworked offline and accepted)

3

3

3

3 4.5 / Booking , Testing & Release of Green Tubes

Uniform Outer Dusting , Booking Tube Temp , - As per Spec and Confirming Standards

Thin Side

(A Portion of the production run may have to be reworked offline and accepted)

3

3 Custom er End

No effect

3

-

3

-

1 -

-

1

-

Thin Spot Booking Tube TempOut of Spec .

(A Portion of the production run may have to be reworked offline and accepted)

(Next 3 Process Valve Blister ) (A Portion of the production Our End run may have to be reworked offline and accepted) 7 Custom er End

(Next Standards Process - Non ) Conformin Our End g Custom er End

No effect Reduced Product Life

(A Portion of the production run may have to be reworked offline and accepted)

No effect

Temp.of Cooling Water on Conveyor - Out of Spec

3

1-Extrusion as per F/QAD/24 . 2-Work execution as per F/PRD/04SOP:02 & W-PRD-09

Temp.of Cooling Water on Conveyor - Out of Spec

2

1-Extrusion as per F/QAD/24 . 2-Work execution as per F/PRD/04SOP:02 & W-PRD-09

3

-

3

1 -

-

1

5

Rheological Properties of Final Compound - Out of Spec

3

Release of Green Tube Trolly - Properties out of Spec .

(Next Green Process W/O Splice 4.6 / Ageing Green Tube Tube (A Portion of the production run may have to be of Green Aged - As per Aged -Not ) Our End scrapped.Deviation from Tubes Spec. As per primary process including Spec decreased line speed or Buckle added man power) (A Portion of the production run may have to be scrapped.Deviation from primary process including decreased line speed or added man power)

-

Custom er End

No effect

-

Release of Green Tubes as per WPRD-26

Current Process Control (Detection) 1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor per F/QAD/11 . 1-Visual by as Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 . 1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 . 1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 . 1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor per F/QAD/11 . 1-Visual by as Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor per F/QAD/11 . 1-Visual by as Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor per F/QAD/11 . 1-Visual by as Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 .

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Daily QA Check Sheet (PFM) -

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Daily QA Check Sheet (PFM) -

1-Every Leaf Truck / Shift by Tech.Suprvisor as per F/QAD/22(GREEN TUBE)

1 1

5 ###

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Identification of Trolly with TAG remarked with Lab OK , Date & Shift .

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Low Operator Skills 4

1-Work execution as per 1-Visual by Operator F/QAD/24/AGEING 2-One Check / Day by QA 2-Skilled Operator deployed Supervisor as per F/QAD/11 . .

Low Operator Skills 4

1-Work execution as per 1-Visual by Operator F/QAD/24/AGEING 2-One Check / Day by QA 2-Skilled Operator deployed Supervisor as per F/QAD/11 . .

Low Operator Skills 2

1-Work execution as per 1-Visual by Operator F/QAD/24/AGEING 2-One Check / Day by QA 2-Skilled Operator deployed Supervisor as per F/QAD/11 . .

Low Operator Skills 2

1-Work execution as per 1-Visual by Operator F/QAD/24/AGEING 2-One Check / Day by QA 2-Skilled Operator deployed Supervisor as per F/QAD/11 . .

3

-

1 -

-

1

-

3

3

7

7 3

-

3

-

1 -

-

1

-

Completi on

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1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 . 1-Visual by Operator 2-Every Size / Shift by Prod.Suprvisor as per F/PRD/12 3-One Check / Day by QA Supervisor as per F/QAD/11 .

Daily QA Check Sheet (PFM) -

1 1

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E - indicates error-proofing Abbreviat P - indicates pokayoka ion : S - indicates special cherecteristics

Revision History S No.

Revision No

Revision Date

Revision Details

Prepared By

Checked by

3 OF 3

& Recomm Target Action Results ended Action(s) Action SDOR

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Daily QA Check Sheet (PFM) -

-

Thin Spot

(A Portion of the production run may have to be reworked offline and accepted)

1-Testing as per F/QAD/24 (RHEO PROP OF FINAL COMP.) 2-Work execution as per F/PRD/04SOP:02 & W-PRD-09

3

Thin Side

(A Portion of the production run may have to be reworked offline and accepted)

Current Process Control (Prevention)

06

Revision D22.04.2021

DETECT RPN

Requirement

Revision Respons No. ibility

Page OCCUR

Sub Process Step/ Function

SEV CLASS

Product

Approved By