Defect History

Sr. No Typeof Defect Action Status

01 Profile NG Cutting Process Revalidate Done

Part Identification and kept

02 Material mixup Done
separate

Thread NG Due to Flux Inside

03 Thread NG Done
now hot waterwasing started

04 Extra material Brazing Validation done Done

100 % Marking Stared after ovality

05 No ovality Done
removal through machine

06 Leakage from Connector Feed back given to operator for Done

 Failure Mode & Effect Analysis Doc. No. EGN/F/DEV/15

(Process FMEA) Date (Org.)

Part Name Pipe Sub Assembly Model YG8-02 Date (Rev.)
Part No. / Rev. No. SB047620-4280 Key Date 17.10.2018 Rev. No.
Customer Name M/s Global Autotech Ltd Dwg. No./Rev. No. SB047620 -4280/A
Core Team M.K Jha, Pramod Kumar, K.P Singh
Current Process Controls Action Results

Severity
Op. No.

Class
Potential Failure Potential Cause(s) / Responsibility & target
Step

RPN
Detecti
Occurr
Process Function Requirement Potential Effect(s) of Failure Recommended Action(s)

ence
Action(s)

RPN
Occ
Sev

Det
Mode Mechanism(s) of Failure completion date

on
Prevention Detection
taken

Mo dent, No End user:

F
Incoming scratch, no No Effect
Inspection & Inspection wrinkle, no extra OEM Assembly: No Effect
1 10
Storage Process edge chips, no Customer Manufacturing Process :No Effect
burn mark ,no Next operation : Fitment NG with mating
flateness part

End user:
Customer dissatisfaction Issuance of wrong spec. matching the issuance slip
OEM Assembly: Unable to assemble at Material from store NA 2 with actual identification 6 84
customer facility & line stop label on the box
Wrong selection
Tube-Dia. Ok Customer Manufacturing Process 7
of tube
:Unable to assemble at customer facility &
line stop wrong selection of box identification with tube
as per operation standard 2 6 84
Next operation : tool damage at bending material in cutting section dia. & thickness

Stopper Position daily equipment check- first piece inspection &

End user: 3 5 90
Disturbed sheet random inspection
No Effect
OEM Assembly: Unable to connect at
Parting Length Ok O/S customer facility 6
Customer Manufacturing Process
preventive maintenance first piece inspection &
:Unable to connect at customer facility Machine condition 3 5 90
check sheet random inspection
Next operation : parts scrap and line stop
2 20 Pipe Cutting

End user: Stopper Position daily equipment check- first piece inspection &
3 5 90
No Effect Disturbed sheet random inspection
OEM Assembly: Unable to connect at
Parting Length Ok U/S customer facility 6
Customer Manufacturing Process
:Unable to connect at customer facility preventive maintenance first piece inspection &
Next operation : parts scrap and line stop Machine condition 3 5 90
check sheet random inspection

End user:
No Effect
No Taper at OEM Assembly: No Effect Multi tube cutting at a random inspection by spl.
Taper Cutting 7 single tube cutting 2 6 84
Cutting Customer Manufacturing Process :No time Gauge
Effect
Next operation : parts scrap

End user:
No Effect
OEM Assembly: No Effect 100% Visual check at
100% Visual check by
3 50 Deburring No Burr Burr Available Customer Manufacturing Process :No 7 Tool Wear out Tool life monitoring 2 7 98 each station by [Link] done
Operator
Effect Operator
Next operation : Fitment NG with mating
part

Ph Value Inadequate Chemical Top-up 2 7 98

Less Washing Time Automation in Machine 2 7 98

4 80 TCE Washing 7
Unclean Water water change daily basis 2 7 98

Improper medium in tank operation standard 2 7 98

 Failure Mode & Effect Analysis Doc. No. EGN/F/DEV/15

(Process FMEA) Date (Org.)

Part Name Pipe Sub Assembly Model YG8-02 Date (Rev.)
Part No. / Rev. No. SB047620-4280 Key Date 17.10.2018 Rev. No.
Customer Name M/s Global Autotech Ltd Dwg. No./Rev. No. SB047620 -4280/A
Core Team M.K Jha, Pramod Kumar, K.P Singh
Current Process Controls Action Results

Severity
Op. No.

Class
Potential Failure Potential Cause(s) / Responsibility & target
Step

RPN
Detecti
Occurr
Process Function Requirement Potential Effect(s) of Failure Recommended Action(s)

ence
Action(s)

RPN
Occ
Sev

Det
Mode Mechanism(s) of Failure completion date

on
Prevention Detection
taken

Bent Portion End user: Low cooling

Bent Portion Dia. Dia. Less Than OEM Assembly: Refrigerant flow rate less equipment daily check
Clamping & Die pressure First 5piece inspection by
2/3 of the Original 2/3 of the Customer Manufacturing Process : Part 7 sheet/ 2 5 70
Less vernier caliper
Pipe Dia Original Pipe NG & line stop Setup Approval
Dia Next operation : Part NG & line stop

Bent Portion End user: Refrigerant leakage

Bent Portion Dia. Dia. Less Than OEM Assembly: Refrigerant leakage equipment daily check
Clamping & Die pressure
2/3 of the Original 2/3 of the Customer Manufacturing Process : Part 7 sheet/ 2 First piece inspection 5 70
Less
Pipe Thickness Original Pipe NG & line stop Setup Approval
Thickness Next operation : Part NG & line stop
5 110 CNC Bending

End user: No effect

OEM Assembly: No Effect First 5piece inspection by
Bending Profile Bending Profile equipment daily check
Customer Manufacturing Process : 7 Hydraulic pressure less 2 vernier caliper/ 5 70
OK Not OK sheet
unable to attach with mating part 100% inspection by Gauge
Next operation : Part NG & line stop

Dent ,
End user: No effect 100% Visual check by
Scratch, No 5 Miss-handling No prevention 2 7 70
OEM Assembly: No Effect Operator
Ovality
Appearance Customer Manufacturing Process :
Wrinkle Customer dissatisfaction Wrong Bending Die
Next operation : Part NG & line stop 7 setup approval 2 100% Visual check 7 98
available setting

End user:
No Effect
OEM Assembly: No Effect 100% Visual check at
100% Visual check by
No Burr Burr Available Customer Manufacturing Process :No 7 Tool Wear out Tool life monitoring 2 7 98 each station by [Link] done
Operator
Effect Operator
Next operation : Fitment NG with mating
part
6 140 Sizing

End user: AC Compressor choked &

intermittent operation
OEM Assembly: Refrigerant leakage 100 % SZING MARK random inspection by spl. 5pcs setup every 4
No Ovality Ovality Available 7 SIZING MISS 2 7 98 [Link] done
Customer Manufacturing Process : IMPLIMENT Gauge hour
Leakage
Next operation : Brazing NG

Less Washing Time Automation in Machine 2 7 98

End user: NO Effect
OEM Assembly: No Effect
No Oil Unclean Water water change daily basis 2 100 % visual inspection by 7 98
7 170 TCE Washing Oil Available Customer Manufacturing Process : 7
contamination operator
Customer dissatisfaction
Next operation :Improper Brazing
Improper medium in tank operation standard 2 7 98

PIN HOLE, BLOW

BRAZING
HOLE, BRAZING
CONDITION GAP NOT ALLOWED

FLUX INSIDE THE

Apperance THREAD OF Less Washing Time Automation in Machine 2 7 98
CONNECTOR End user:
No Effect
Brazing NO EXCESS OEM Assembly: No Effect
PREHEATING HEATING 100 % visual inspection by
8 200 (SB047620- CONDITION ALLOWED BY Customer Manufacturing Process :No 7 Unclean Water water change daily basis 2 7 98
operator
4280) FLAME Effect
Next operation : Fitment NG with mating
part
 Failure Mode & Effect Analysis Doc. No. EGN/F/DEV/15

(Process FMEA) Date (Org.)

Part Name Pipe Sub Assembly Model YG8-02 Date (Rev.)
Part No. / Rev. No. SB047620-4280 Key Date 17.10.2018 Rev. No.
Customer Name M/s Global Autotech Ltd Dwg. No./Rev. No. SB047620 -4280/A
Core Team M.K Jha, Pramod Kumar, K.P Singh End user:
No Effect Current Process Controls Action Results

Severity
Op. No.

Brazing Potential Failure OEM Assembly: No Effect

Class
Potential Cause(s) / Responsibility & target
Step

RPN
Detecti
100 % visual inspection by

Occurr
Process Function Requirement Potential Effect(s) of Failure Recommended Action(s)

ence
Action(s)

RPN
8 200 (SB047620- Customer Manufacturing Process :No 7

Occ
Sev

Det
Mode Mechanism(s) of Failure completion date

on
Prevention Detection
operator
4280) Effect taken
Next operation : Fitment NG with mating
BRAZING AS PER BRAZING part
FIXTURE.
ORIENTATIO\N

No burn marks, no
Apperance flateness,no leakage Improper medium in tank operation standard 2 7 98

NO EXTRA FLUX ,
NO BURN,NO PIN
HOLE,EXTRA
MATERIAL NOT
ALLOW,WRONG
CHILD PART,No
End user:
burn marks, no No Effect Less Washing Time Automation in Machine 2 7 98
flateness,no leakage OEM Assembly: No Effect
Brazing 100 % visual inspection by
9 230 Appearane Customer Manufacturing Process :No 7
Inspection operator/ Qa engineer
Effect
Next operation : Fitment NG with mating
part Unclean Water water change daily basis 2 7 98
BRAZING FILLET IN
CUT SECTION

Improper medium in tank operation standard 2 7 98

NO
Appearane CONTAMINATION Checking Visual As per standard
End user:
No Effect
OEM Assembly: No Effect
Hot RO Water 100 % visual inspection by
10 260 Appearane Time / Temprature Customer Manufacturing Process :No 7 Less Washing Time Automation in Machine 2 7 98
Cleaning operator/ Qa engineer
Effect
Next operation : Fitment NG with mating
part Qty Dip more than
Appearane Dipping Qty in tank operation standard 2 7 98
standard

Manual inspection Work -Instruction 2 7 98

NO DENT, NO
Appearance SCRATCH,NO
CHIPS Checking gauge Not Checking Gauge
2 7 98
Validate Validation plan

End user: No Effect

operator competency
Profile Not Ok OEM Assembly: No Effect skill level min 2 2 7 98
level
Customer Manufacturing Process: unable
11 290 Final Gauging 7 Pre dispatch inspection
to attach with mating part
Next operation: Part NG & FG Transfer operator competency
Bulging OD U/S or O/S skill level min 2 2 7 98
Stop level

Pin provided in Final

Tube Connector operator competency assy gauge to detect
Not OK skill level min 2 2 7 98 rakesh done 7 2 5 70
Orientation level the wrong tube
connector

Mixing of Parts /
12 320 Packing Packing Ok Wrong Part Customer Dissatisfaction 5 manual inspection packing standard 2 Pre dispatch inspection 7 70
Label

Mo dent, No
End user: No Effect
Appearance scratch, no
OEM Assembly: No Effect
&Critical wrinkle, no extra
13 350 PDI Customer Manufacturing Process: unable to manual inspection As per spec Pre dispatch inspection
Dimensions as edge chips, no
attach with mating part
per IT plan burn mark ,no
Next operation: Part NG & FG Transfer Stop
flateness

Rev Change Description Rev. Date Prepared By Checked By Approved By

 Failure Mode & Effect Analysis Doc. No. EGN/F/DEV/15

(Process FMEA) Date (Org.)

Part Name Pipe Sub Assembly Model YL1/YL8LH Date (Rev.)
Part No. / Rev. No. SB047620-4260 Key Date 17.10.2018 Rev. No.
Customer Name M/s Global Autotech Ltd Dwg. No./Rev. No. SB047620 -4260/A
Core Team M.K Jha, Pramod Kumar, K.P Singh
Current Process Controls Action Results

Severity
Op. No.

Class
Potential Failure Potential Cause(s) / Responsibility & target
Step

RPN
Detecti
Occurr
Process Function Requirement Potential Effect(s) of Failure Recommended Action(s)

ence
Action(s)

RPN
Occ
Sev

Det
Mode Mechanism(s) of Failure completion date

on
Prevention Detection
taken

Mo dent, No End user:

F
Incoming scratch, no No Effect
Inspection & Inspection wrinkle, no extra OEM Assembly: No Effect
1 10
Storage Process edge chips, no Customer Manufacturing Process :No Effect
burn mark ,no Next operation : Fitment NG with mating
flateness part

End user:
Customer dissatisfaction Issuance of wrong spec. matching the issuance slip
OEM Assembly: Unable to assemble at Material from store NA 2 with actual identification 6 84
customer facility & line stop label on the box
Wrong selection
Tube-Dia. Ok Customer Manufacturing Process 7
of tube
:Unable to assemble at customer facility &
line stop wrong selection of box identification with tube
as per operation standard 2 6 84
Next operation : tool damage at bending material in cutting section dia. & thickness

Stopper Position daily equipment check- first piece inspection &

End user: 3 5 90
Disturbed sheet random inspection
No Effect
OEM Assembly: Unable to connect at
Parting Length Ok O/S customer facility 6
Customer Manufacturing Process
preventive maintenance first piece inspection &
:Unable to connect at customer facility Machine condition 3 5 90
check sheet random inspection
Next operation : parts scrap and line stop
2 20 Pipe Cutting

End user: Stopper Position daily equipment check- first piece inspection &
3 5 90
No Effect Disturbed sheet random inspection
OEM Assembly: Unable to connect at
Parting Length Ok U/S customer facility 6
Customer Manufacturing Process
:Unable to connect at customer facility preventive maintenance first piece inspection &
Next operation : parts scrap and line stop Machine condition 3 5 90
check sheet random inspection

End user:
No Effect
No Taper at OEM Assembly: No Effect Multi tube cutting at a random inspection by spl.
Taper Cutting 7 single tube cutting 2 6 84
Cutting Customer Manufacturing Process :No time Gauge
Effect
Next operation : parts scrap

End user:
No Effect
OEM Assembly: No Effect 100% Visual check at
100% Visual check by
3 50 Deburring No Burr Burr Available Customer Manufacturing Process :No 7 Tool Wear out Tool life monitoring 2 7 98 each station by [Link] done
Operator
Effect Operator
Next operation : Fitment NG with mating
part

Ph Value Inadequate Chemical Top-up 2 7 98

Less Washing Time Automation in Machine 2 7 98

4 80 TCE Washing 7
Unclean Water water change daily basis 2 7 98

Improper medium in tank operation standard 2 7 98

 Failure Mode & Effect Analysis Doc. No. EGN/F/DEV/15

(Process FMEA) Date (Org.)

Part Name Pipe Sub Assembly Model YL1/YL8LH Date (Rev.)
Part No. / Rev. No. SB047620-4260 Key Date 17.10.2018 Rev. No.
Customer Name M/s Global Autotech Ltd Dwg. No./Rev. No. SB047620 -4260/A
Core Team M.K Jha, Pramod Kumar, K.P Singh
Current Process Controls Action Results

Severity
Op. No.

Class
Potential Failure Potential Cause(s) / Responsibility & target
Step

RPN
Detecti
Occurr
Process Function Requirement Potential Effect(s) of Failure Recommended Action(s)

ence
Action(s)

RPN
Occ
Sev

Det
Mode Mechanism(s) of Failure completion date

on
Prevention Detection
taken

Bent Portion End user: Low cooling

Bent Portion Dia. Dia. Less Than OEM Assembly: Refrigerant flow rate less equipment daily check
Clamping & Die pressure First 5piece inspection by
2/3 of the Original 2/3 of the Customer Manufacturing Process : Part 7 sheet/ 2 5 70
Less vernier caliper
Pipe Dia Original Pipe NG & line stop Setup Approval
Dia Next operation : Part NG & line stop

Bent Portion End user: Refrigerant leakage

Bent Portion Dia. Dia. Less Than OEM Assembly: Refrigerant leakage equipment daily check
Clamping & Die pressure
2/3 of the Original 2/3 of the Customer Manufacturing Process : Part 7 sheet/ 2 First piece inspection 5 70
Less
Pipe Thickness Original Pipe NG & line stop Setup Approval
Thickness Next operation : Part NG & line stop
5 110 CNC Bending

End user: No effect

OEM Assembly: No Effect First 5piece inspection by
Bending Profile Bending Profile equipment daily check
Customer Manufacturing Process : 7 Hydraulic pressure less 2 vernier caliper/ 5 70
OK Not OK sheet
unable to attach with mating part 100% inspection by Gauge
Next operation : Part NG & line stop

Dent ,
End user: No effect 100% Visual check by
Scratch, No 5 Miss-handling No prevention 2 7 70
OEM Assembly: No Effect Operator
Ovality
Appearance Customer Manufacturing Process :
Wrinkle Customer dissatisfaction Wrong Bending Die
Next operation : Part NG & line stop 7 setup approval 2 100% Visual check 7 98
available setting

End user:
No Effect
OEM Assembly: No Effect 100% Visual check at
100% Visual check by
No Burr Burr Available Customer Manufacturing Process :No 7 Tool Wear out Tool life monitoring 2 7 98 each station by [Link] done
Operator
Effect Operator
Next operation : Fitment NG with mating
part
6 140 Sizing

End user: AC Compressor choked &

intermittent operation
OEM Assembly: Refrigerant leakage 100 % SZING MARK random inspection by spl. 5pcs setup every 4
No Ovality Ovality Available 7 SIZING MISS 2 7 98 [Link] done
Customer Manufacturing Process : IMPLIMENT Gauge hour
Leakage
Next operation : Brazing NG

Less Washing Time Automation in Machine 2 7 98

End user: NO Effect
OEM Assembly: No Effect
No Oil Unclean Water water change daily basis 2 100 % visual inspection by 7 98
7 170 TCE Washing Oil Available Customer Manufacturing Process : 7
contamination operator
Customer dissatisfaction
Next operation :Improper Brazing
Improper medium in tank operation standard 2 7 98

PIN HOLE, BLOW

BRAZING
HOLE, BRAZING
CONDITION GAP NOT ALLOWED

FLUX INSIDE THE

Apperance THREAD OF Less Washing Time Automation in Machine 2 7 98
CONNECTOR End user:
No Effect
Brazing NO EXCESS OEM Assembly: No Effect
PREHEATING HEATING 100 % visual inspection by
8 200 (SB047620- CONDITION ALLOWED BY Customer Manufacturing Process :No 7 Unclean Water water change daily basis 2 7 98
operator
4260) FLAME Effect
Next operation : Fitment NG with mating
part
 Failure Mode & Effect Analysis Doc. No. EGN/F/DEV/15

(Process FMEA) Date (Org.)

Part Name Pipe Sub Assembly Model YL1/YL8LH Date (Rev.)
Part No. / Rev. No. SB047620-4260 Key Date 17.10.2018 Rev. No.
Customer Name M/s Global Autotech Ltd Dwg. No./Rev. No. SB047620 -4260/A
Core Team M.K Jha, Pramod Kumar, K.P Singh End user:
No Effect Current Process Controls Action Results

Severity
Op. No.

Brazing Potential Failure OEM Assembly: No Effect

Class
Potential Cause(s) / Responsibility & target
Step

RPN
Detecti
100 % visual inspection by

Occurr
Process Function Requirement Potential Effect(s) of Failure Recommended Action(s)

ence
Action(s)

RPN
8 200 (SB047620- Customer Manufacturing Process :No 7

Occ
Sev

Det
Mode Mechanism(s) of Failure completion date

on
Prevention Detection
operator
4260) Effect taken
Next operation : Fitment NG with mating
BRAZING AS PER BRAZING part
FIXTURE.
ORIENTATIO\N

No burn marks, no
Apperance flateness,no leakage Improper medium in tank operation standard 2 7 98

NO EXTRA FLUX ,
NO BURN,NO PIN
HOLE,EXTRA
MATERIAL NOT
ALLOW,WRONG
CHILD PART,No
End user:
burn marks, no No Effect Less Washing Time Automation in Machine 2 7 98
flateness,no leakage OEM Assembly: No Effect
Brazing 100 % visual inspection by
9 230 Appearane Customer Manufacturing Process :No 7
Inspection operator/ Qa engineer
Effect
Next operation : Fitment NG with mating
part Unclean Water water change daily basis 2 7 98
BRAZING FILLET IN
CUT SECTION

Improper medium in tank operation standard 2 7 98

NO
Appearane CONTAMINATION Checking Visual As per standard
End user:
No Effect
OEM Assembly: No Effect
Hot RO Water 100 % visual inspection by
10 260 Appearane Time / Temprature Customer Manufacturing Process :No 7 Less Washing Time Automation in Machine 2 7 98
Cleaning operator/ Qa engineer
Effect
Next operation : Fitment NG with mating
part Qty Dip more than
Appearane Dipping Qty in tank operation standard 2 7 98
standard

Manual inspection Work -Instruction 2 7 98

NO DENT, NO
Appearance SCRATCH,NO
CHIPS Checking gauge Not Checking Gauge
2 7 98
Validate Validation plan

End user: No Effect

operator competency
Profile Not Ok OEM Assembly: No Effect skill level min 2 2 7 98
level
Customer Manufacturing Process: unable
11 290 Final Gauging 7 Pre dispatch inspection
to attach with mating part
Next operation: Part NG & FG Transfer operator competency
Bulging OD U/S or O/S skill level min 2 2 7 98
Stop level

Pin provided in Final

Tube Connector operator competency assy gauge to detect
Not OK skill level min 2 2 7 98 rakesh done 7 2 5 70
Orientation level the wrong tube
connector

Mixing of Parts /
12 320 Packing Packing Ok Wrong Part Customer Dissatisfaction 5 manual inspection packing standard 2 Pre dispatch inspection 7 70
Label

Mo dent, No
End user: No Effect
Appearance scratch, no
OEM Assembly: No Effect
&Critical wrinkle, no extra
13 350 PDI Customer Manufacturing Process: unable to manual inspection As per spec Pre dispatch inspection
Dimensions as edge chips, no
attach with mating part
per IT plan burn mark ,no
Next operation: Part NG & FG Transfer Stop
flateness

Rev Change Description Rev. Date Prepared By Checked By Approved By

 Failure Mode & Effect Analysis Doc. No. EGN/F/DEV/15

(Process FMEA) Date (Org.)

Part Name Pipe Sub Assembly Model YL1-RH Date (Rev.)
Part No. / Rev. No. SB047620-4240 Key Date 17.10.2018 Rev. No.
Customer Name M/s Global Autotech Ltd Dwg. No./Rev. No. SB047620 -4240/A
Core Team M.K Jha, Pramod Kumar, K.P Singh
Current Process Controls Action Results

Severity
Op. No.

Class
Potential Failure Potential Cause(s) / Responsibility & target
Step

RPN
Detecti
Occurr
Process Function Requirement Potential Effect(s) of Failure Recommended Action(s)

ence
Action(s)

RPN
Occ
Sev

Det
Mode Mechanism(s) of Failure completion date

on
Prevention Detection
taken

Mo dent, No End user:

F
Incoming scratch, no No Effect
Inspection & Inspection wrinkle, no extra OEM Assembly: No Effect
1 10
Storage Process edge chips, no Customer Manufacturing Process :No Effect
burn mark ,no Next operation : Fitment NG with mating
flateness part

End user:
Customer dissatisfaction Issuance of wrong spec. matching the issuance slip
OEM Assembly: Unable to assemble at Material from store NA 2 with actual identification 6 84
customer facility & line stop label on the box
Wrong selection
Tube-Dia. Ok Customer Manufacturing Process 7
of tube
:Unable to assemble at customer facility &
line stop wrong selection of box identification with tube
as per operation standard 2 6 84
Next operation : tool damage at bending material in cutting section dia. & thickness

Stopper Position daily equipment check- first piece inspection &

End user: 3 5 90
Disturbed sheet random inspection
No Effect
OEM Assembly: Unable to connect at
Parting Length Ok O/S customer facility 6
Customer Manufacturing Process
preventive maintenance first piece inspection &
:Unable to connect at customer facility Machine condition 3 5 90
check sheet random inspection
Next operation : parts scrap and line stop
2 20 Pipe Cutting

End user: Stopper Position daily equipment check- first piece inspection &
3 5 90
No Effect Disturbed sheet random inspection
OEM Assembly: Unable to connect at
Parting Length Ok U/S customer facility 6
Customer Manufacturing Process
:Unable to connect at customer facility preventive maintenance first piece inspection &
Next operation : parts scrap and line stop Machine condition 3 5 90
check sheet random inspection

End user:
No Effect
No Taper at OEM Assembly: No Effect Multi tube cutting at a random inspection by spl.
Taper Cutting 7 single tube cutting 2 6 84
Cutting Customer Manufacturing Process :No time Gauge
Effect
Next operation : parts scrap

End user:
No Effect
OEM Assembly: No Effect 100% Visual check at
100% Visual check by
3 50 Deburring No Burr Burr Available Customer Manufacturing Process :No 7 Tool Wear out Tool life monitoring 2 7 98 each station by [Link] done
Operator
Effect Operator
Next operation : Fitment NG with mating
part

Ph Value Inadequate Chemical Top-up 2 7 98

Less Washing Time Automation in Machine 2 7 98

4 80 TCE Washing 7
Unclean Water water change daily basis 2 7 98

Improper medium in tank operation standard 2 7 98

 Failure Mode & Effect Analysis Doc. No. EGN/F/DEV/15

(Process FMEA) Date (Org.)

Part Name Pipe Sub Assembly Model YL1-RH Date (Rev.)
Part No. / Rev. No. SB047620-4240 Key Date 17.10.2018 Rev. No.
Customer Name M/s Global Autotech Ltd Dwg. No./Rev. No. SB047620 -4240/A
Core Team M.K Jha, Pramod Kumar, K.P Singh
Current Process Controls Action Results

Severity
Op. No.

Class
Potential Failure Potential Cause(s) / Responsibility & target
Step

RPN
Detecti
Occurr
Process Function Requirement Potential Effect(s) of Failure Recommended Action(s)

ence
Action(s)

RPN
Occ
Sev

Det
Mode Mechanism(s) of Failure completion date

on
Prevention Detection
taken

Bent Portion End user: Low cooling

Bent Portion Dia. Dia. Less Than OEM Assembly: Refrigerant flow rate less equipment daily check
Clamping & Die pressure First 5piece inspection by
2/3 of the Original 2/3 of the Customer Manufacturing Process : Part 7 sheet/ 2 5 70
Less vernier caliper
Pipe Dia Original Pipe NG & line stop Setup Approval
Dia Next operation : Part NG & line stop

Bent Portion End user: Refrigerant leakage

Bent Portion Dia. Dia. Less Than OEM Assembly: Refrigerant leakage equipment daily check
Clamping & Die pressure
2/3 of the Original 2/3 of the Customer Manufacturing Process : Part 7 sheet/ 2 First piece inspection 5 70
Less
Pipe Thickness Original Pipe NG & line stop Setup Approval
Thickness Next operation : Part NG & line stop
5 110 CNC Bending

End user: No effect

OEM Assembly: No Effect First 5piece inspection by
Bending Profile Bending Profile equipment daily check
Customer Manufacturing Process : 7 Hydraulic pressure less 2 vernier caliper/ 5 70
OK Not OK sheet
unable to attach with mating part 100% inspection by Gauge
Next operation : Part NG & line stop

Dent ,
End user: No effect 100% Visual check by
Scratch, No 5 Miss-handling No prevention 2 7 70
OEM Assembly: No Effect Operator
Ovality
Appearance Customer Manufacturing Process :
Wrinkle Customer dissatisfaction Wrong Bending Die
Next operation : Part NG & line stop 7 setup approval 2 100% Visual check 7 98
available setting

End user:
No Effect
OEM Assembly: No Effect 100% Visual check at
100% Visual check by
No Burr Burr Available Customer Manufacturing Process :No 7 Tool Wear out Tool life monitoring 2 7 98 each station by [Link] done
Operator
Effect Operator
Next operation : Fitment NG with mating
part
6 140 Sizing

End user: AC Compressor choked &

intermittent operation
OEM Assembly: Refrigerant leakage 100 % SZING MARK random inspection by spl. 5pcs setup every 4
No Ovality Ovality Available 7 SIZING MISS 2 7 98 [Link] done
Customer Manufacturing Process : IMPLIMENT Gauge hour
Leakage
Next operation : Brazing NG

Less Washing Time Automation in Machine 2 7 98

End user: NO Effect
OEM Assembly: No Effect
No Oil Unclean Water water change daily basis 2 100 % visual inspection by 7 98
7 170 TCE Washing Oil Available Customer Manufacturing Process : 7
contamination operator
Customer dissatisfaction
Next operation :Improper Brazing
Improper medium in tank operation standard 2 7 98

PIN HOLE, BLOW

BRAZING
HOLE, BRAZING
CONDITION GAP NOT ALLOWED

FLUX INSIDE THE

Apperance THREAD OF Less Washing Time Automation in Machine 2 7 98
CONNECTOR End user:
No Effect
Brazing NO EXCESS OEM Assembly: No Effect
PREHEATING HEATING 100 % visual inspection by
8 200 (SB047620- CONDITION ALLOWED BY Customer Manufacturing Process :No 7 Unclean Water water change daily basis 2 7 98
operator
4240) FLAME Effect
Next operation : Fitment NG with mating
part
 Failure Mode & Effect Analysis Doc. No. EGN/F/DEV/15

(Process FMEA) Date (Org.)

Part Name Pipe Sub Assembly Model YL1-RH Date (Rev.)
Part No. / Rev. No. SB047620-4240 Key Date 17.10.2018 Rev. No.
Customer Name M/s Global Autotech Ltd Dwg. No./Rev. No. SB047620 -4240/A
Core Team M.K Jha, Pramod Kumar, K.P Singh End user:
No Effect Current Process Controls Action Results

Severity
Op. No.

Brazing Potential Failure OEM Assembly: No Effect

Class
Potential Cause(s) / Responsibility & target
Step

RPN
Detecti
100 % visual inspection by

Occurr
Process Function Requirement Potential Effect(s) of Failure Recommended Action(s)

ence
Action(s)

RPN
8 200 (SB047620- Customer Manufacturing Process :No 7

Occ
Sev

Det
Mode Mechanism(s) of Failure completion date

on
Prevention Detection
operator
4240) Effect taken
Next operation : Fitment NG with mating
BRAZING AS PER BRAZING part
FIXTURE.
ORIENTATIO\N

No burn marks, no
Apperance flateness,no leakage Improper medium in tank operation standard 2 7 98

NO EXTRA FLUX ,
NO BURN,NO PIN
HOLE,EXTRA
MATERIAL NOT
ALLOW,WRONG
CHILD PART,No
End user:
burn marks, no No Effect Less Washing Time Automation in Machine 2 7 98
flateness,no leakage OEM Assembly: No Effect
Brazing 100 % visual inspection by
9 230 Appearane Customer Manufacturing Process :No 7
Inspection operator/ Qa engineer
Effect
Next operation : Fitment NG with mating
part Unclean Water water change daily basis 2 7 98
BRAZING FILLET IN
CUT SECTION

Improper medium in tank operation standard 2 7 98

NO
Appearane CONTAMINATION Checking Visual As per standard
End user:
No Effect
OEM Assembly: No Effect
Hot RO Water 100 % visual inspection by
10 260 Appearane Time / Temprature Customer Manufacturing Process :No 7 Less Washing Time Automation in Machine 2 7 98
Cleaning operator/ Qa engineer
Effect
Next operation : Fitment NG with mating
part Qty Dip more than
Appearane Dipping Qty in tank operation standard 2 7 98
standard

Manual inspection Work -Instruction 2 7 98

NO DENT, NO
Appearance SCRATCH,NO
CHIPS Checking gauge Not Checking Gauge
2 7 98
Validate Validation plan

End user: No Effect

operator competency
Profile Not Ok OEM Assembly: No Effect skill level min 2 2 7 98
level
Customer Manufacturing Process: unable
11 290 Final Gauging 7 Pre dispatch inspection
to attach with mating part
Next operation: Part NG & FG Transfer operator competency
Bulging OD U/S or O/S skill level min 2 2 7 98
Stop level

Pin provided in Final

Tube Connector operator competency assy gauge to detect
Not OK skill level min 2 2 7 98 rakesh done 7 2 5 70
Orientation level the wrong tube
connector

Mixing of Parts /
12 320 Packing Packing Ok Wrong Part Customer Dissatisfaction 5 manual inspection packing standard 2 Pre dispatch inspection 7 70
Label

Mo dent, No
End user: No Effect
Appearance scratch, no
OEM Assembly: No Effect
&Critical wrinkle, no extra
13 350 PDI Customer Manufacturing Process: unable to manual inspection As per spec Pre dispatch inspection
Dimensions as edge chips, no
attach with mating part
per IT plan burn mark ,no
Next operation: Part NG & FG Transfer Stop
flateness

Rev Change Description Rev. Date Prepared By Checked By Approved By

 Failure Mode & Effect Analysis Doc. No. EGN/F/DEV/15

(Process FMEA) Date (Org.)

Part Name Pipe Sub Assembly Model YAD Date (Rev.)
Part No. / Rev. No. SB447660-1350 Key Date 17.10.2018 Rev. No.
Customer Name M/s Global Autotech Ltd Dwg. No./Rev. No. 447660-1350, A
Core Team M.K Jha, Pramod Kumar, K.P Singh
Current Process Controls Action Results

Severity
Op. No.

Class
Potential Failure Potential Cause(s) / Responsibility & target
Step

RPN
Detecti
Occurr
Process Function Requirement Potential Effect(s) of Failure Recommended Action(s)

ence
Action(s)

RPN
Occ
Sev

Det
Mode Mechanism(s) of Failure completion date

on
Prevention Detection
taken

Mo dent, No End user:

F
Incoming scratch, no No Effect
Inspection & Inspection wrinkle, no extra OEM Assembly: No Effect
1 10
Storage Process edge chips, no Customer Manufacturing Process :No Effect
burn mark ,no Next operation : Fitment NG with mating
flateness part

End user:
Customer dissatisfaction Issuance of wrong spec. matching the issuance slip
OEM Assembly: Unable to assemble at Material from store NA 2 with actual identification 6 84
customer facility & line stop label on the box
Wrong selection
Tube-Dia. Ok Customer Manufacturing Process 7
of tube
:Unable to assemble at customer facility &
line stop wrong selection of box identification with tube
as per operation standard 2 6 84
Next operation : tool damage at bending material in cutting section dia. & thickness

Stopper Position daily equipment check- first piece inspection &

End user: 3 5 90
Disturbed sheet random inspection
No Effect
OEM Assembly: Unable to connect at
Parting Length Ok O/S customer facility 6
Customer Manufacturing Process
preventive maintenance first piece inspection &
:Unable to connect at customer facility Machine condition 3 5 90
check sheet random inspection
Next operation : parts scrap and line stop
2 20 Pipe Cutting

End user: Stopper Position daily equipment check- first piece inspection &
3 5 90
No Effect Disturbed sheet random inspection
OEM Assembly: Unable to connect at
Parting Length Ok U/S customer facility 6
Customer Manufacturing Process
:Unable to connect at customer facility preventive maintenance first piece inspection &
Next operation : parts scrap and line stop Machine condition 3 5 90
check sheet random inspection

End user:
No Effect
No Taper at OEM Assembly: No Effect Multi tube cutting at a random inspection by spl.
Taper Cutting 7 single tube cutting 2 6 84
Cutting Customer Manufacturing Process :No time Gauge
Effect
Next operation : parts scrap

End user:
No Effect
OEM Assembly: No Effect 100% Visual check at
100% Visual check by
3 50 Deburring No Burr Burr Available Customer Manufacturing Process :No 7 Tool Wear out Tool life monitoring 2 7 98 each station by [Link] done
Operator
Effect Operator
Next operation : Fitment NG with mating
part

Ph Value Inadequate Chemical Top-up 2 7 98

Less Washing Time Automation in Machine 2 7 98

4 80 TCE Washing 7
Unclean Water water change daily basis 2 7 98

Improper medium in tank operation standard 2 7 98

 Failure Mode & Effect Analysis Doc. No. EGN/F/DEV/15

(Process FMEA) Date (Org.)

Part Name Pipe Sub Assembly Model YAD Date (Rev.)
Part No. / Rev. No. SB447660-1350 Key Date 17.10.2018 Rev. No.
Customer Name M/s Global Autotech Ltd Dwg. No./Rev. No. 447660-1350, A
Core Team M.K Jha, Pramod Kumar, K.P Singh
Current Process Controls Action Results

Severity
Op. No.

Class
Potential Failure Potential Cause(s) / Responsibility & target
Step

RPN
Detecti
Occurr
Process Function Requirement Potential Effect(s) of Failure Recommended Action(s)

ence
Action(s)

RPN
Occ
Sev

Det
Mode Mechanism(s) of Failure completion date

on
Prevention Detection
taken

Bent Portion End user: Low cooling

Bent Portion Dia. Dia. Less Than OEM Assembly: Refrigerant flow rate less equipment daily check
Clamping & Die pressure First 5piece inspection by
2/3 of the Original 2/3 of the Customer Manufacturing Process : Part 7 sheet/ 2 5 70
Less vernier caliper
Pipe Dia Original Pipe NG & line stop Setup Approval
Dia Next operation : Part NG & line stop

Bent Portion End user: Refrigerant leakage

Bent Portion Dia. Dia. Less Than OEM Assembly: Refrigerant leakage equipment daily check
Clamping & Die pressure
2/3 of the Original 2/3 of the Customer Manufacturing Process : Part 7 sheet/ 2 First piece inspection 5 70
Less
Pipe Thickness Original Pipe NG & line stop Setup Approval
Thickness Next operation : Part NG & line stop
5 110 CNC Bending

End user: No effect

OEM Assembly: No Effect First 5piece inspection by
Bending Profile Bending Profile equipment daily check
Customer Manufacturing Process : 7 Hydraulic pressure less 2 vernier caliper/ 5 70
OK Not OK sheet
unable to attach with mating part 100% inspection by Gauge
Next operation : Part NG & line stop

Dent ,
End user: No effect 100% Visual check by
Scratch, No 5 Miss-handling No prevention 2 7 70
OEM Assembly: No Effect Operator
Ovality
Appearance Customer Manufacturing Process :
Wrinkle Customer dissatisfaction Wrong Bending Die
Next operation : Part NG & line stop 7 setup approval 2 100% Visual check 7 98
available setting

End user:
No Effect
OEM Assembly: No Effect 100% Visual check at
100% Visual check by
No Burr Burr Available Customer Manufacturing Process :No 7 Tool Wear out Tool life monitoring 2 7 98 each station by [Link] done
Operator
Effect Operator
Next operation : Fitment NG with mating
part
6 140 Sizing

End user: AC Compressor choked &

intermittent operation
OEM Assembly: Refrigerant leakage 100 % SZING MARK random inspection by spl. 5pcs setup every 4
No Ovality Ovality Available 7 SIZING MISS 2 7 98 [Link] done
Customer Manufacturing Process : IMPLIMENT Gauge hour
Leakage
Next operation : Brazing NG

Less Washing Time Automation in Machine 2 7 98

End user: NO Effect
OEM Assembly: No Effect
No Oil Unclean Water water change daily basis 2 100 % visual inspection by 7 98
7 170 TCE Washing Oil Available Customer Manufacturing Process : 7
contamination operator
Customer dissatisfaction
Next operation :Improper Brazing
Improper medium in tank operation standard 2 7 98

PIN HOLE, BLOW

BRAZING
HOLE, BRAZING
CONDITION GAP NOT ALLOWED

FLUX INSIDE THE

Apperance THREAD OF Less Washing Time Automation in Machine 2 7 98
CONNECTOR End user:
No Effect
NO EXCESS OEM Assembly: No Effect
Brazing PREHEATING HEATING 100 % visual inspection by
8 200 Customer Manufacturing Process :No 7 Unclean Water water change daily basis 2 7 98
(447660-1350 CONDITION ALLOWED BY operator
FLAME Effect
Next operation : Fitment NG with mating
part
 Failure Mode & Effect Analysis Doc. No. EGN/F/DEV/15

(Process FMEA) Date (Org.)

Part Name Pipe Sub Assembly Model YAD Date (Rev.)
Part No. / Rev. No. SB447660-1350 Key Date 17.10.2018 Rev. No.
Customer Name M/s Global Autotech Ltd Dwg. No./Rev. No. 447660-1350, A
Core Team M.K Jha, Pramod Kumar, K.P Singh End user:
No Effect Current Process Controls Action Results

Severity
Op. No.

Potential Failure OEM Assembly: No Effect

Class
Potential Cause(s) / Responsibility & target
Step

RPN
Detecti
Brazing 100 % visual inspection by

Occurr
Process Function Requirement Potential Effect(s) of Failure Recommended Action(s)

ence
Action(s)

RPN
8 200 Customer Manufacturing Process :No 7

Occ
Sev

Det
Mode Mechanism(s) of Failure completion date

on
(447660-1350 Prevention Detection
operator
Effect taken
Next operation : Fitment NG with mating
BRAZING AS PER BRAZING part
FIXTURE.
ORIENTATIO\N

No burn marks, no
Apperance flateness,no leakage Improper medium in tank operation standard 2 7 98

NO EXTRA FLUX ,
NO BURN,NO PIN
HOLE,EXTRA
MATERIAL NOT
ALLOW,WRONG
CHILD PART,No
End user:
burn marks, no No Effect Less Washing Time Automation in Machine 2 7 98
flateness,no leakage OEM Assembly: No Effect
Brazing 100 % visual inspection by
9 230 Appearane Customer Manufacturing Process :No 7
Inspection operator/ Qa engineer
Effect
Next operation : Fitment NG with mating
part Unclean Water water change daily basis 2 7 98
BRAZING FILLET IN
CUT SECTION

Improper medium in tank operation standard 2 7 98

NO
Appearane CONTAMINATION Checking Visual As per standard
End user:
No Effect
OEM Assembly: No Effect
Hot RO Water 100 % visual inspection by
10 260 Appearane Time / Temprature Customer Manufacturing Process :No 7 Less Washing Time Automation in Machine 2 7 98
Cleaning operator/ Qa engineer
Effect
Next operation : Fitment NG with mating
part Qty Dip more than
Appearane Dipping Qty in tank operation standard 2 7 98
standard

Manual inspection Work -Instruction 2 7 98

NO DENT, NO
Appearance SCRATCH,NO
CHIPS Checking gauge Not Checking Gauge
2 7 98
Validate Validation plan

End user: No Effect

operator competency
Profile Not Ok OEM Assembly: No Effect skill level min 2 2 7 98
level
Customer Manufacturing Process: unable
11 290 Final Gauging 7 Pre dispatch inspection
to attach with mating part
Next operation: Part NG & FG Transfer operator competency
Bulging OD U/S or O/S skill level min 2 2 7 98
Stop level

Pin provided in Final

Tube Connector operator competency assy gauge to detect
Not OK skill level min 2 2 7 98 rakesh done 7 2 5 70
Orientation level the wrong tube
connector

Mixing of Parts /
12 320 Packing Packing Ok Wrong Part Customer Dissatisfaction 5 manual inspection packing standard 2 Pre dispatch inspection 7 70
Label

Mo dent, No
End user: No Effect
Appearance scratch, no
OEM Assembly: No Effect
&Critical wrinkle, no extra
13 350 PDI Customer Manufacturing Process: unable to manual inspection As per spec Pre dispatch inspection
Dimensions as edge chips, no
attach with mating part
per IT plan burn mark ,no
Next operation: Part NG & FG Transfer Stop
flateness

Rev Change Description Rev. Date Prepared By Checked By Approved By

 Failure Mode & Effect Analysis Doc. No. EGN/F/DEV/15

(Process FMEA) Date (Org.)

Part Name Pipe Sub Assembly Model YN4 Date (Rev.)
Part No. / Rev. No. 447660-0530 Key Date 17.10.2018 Rev. No.
Customer Name M/s Global Autotech Ltd Dwg. No./Rev. No. 447660-0530, 0
Core Team M.K Jha, Pramod Kumar, K.P Singh
Current Process Controls Action Results

Severity
Op. No.

Class
Potential Failure Potential Cause(s) / Responsibility & target
Step

RPN
Detecti
Occurr
Process Function Requirement Potential Effect(s) of Failure Recommended Action(s)

ence
Action(s)

RPN
Occ
Sev

Det
Mode Mechanism(s) of Failure completion date

on
Prevention Detection
taken

Mo dent, No End user:

F
Incoming scratch, no No Effect
Inspection & Inspection wrinkle, no extra OEM Assembly: No Effect
1 10
Storage Process edge chips, no Customer Manufacturing Process :No Effect
burn mark ,no Next operation : Fitment NG with mating
flateness part

End user:
Customer dissatisfaction Issuance of wrong spec. matching the issuance slip
OEM Assembly: Unable to assemble at Material from store NA 2 with actual identification 6 84
customer facility & line stop label on the box
Wrong selection
Tube-Dia. Ok Customer Manufacturing Process 7
of tube
:Unable to assemble at customer facility &
line stop wrong selection of box identification with tube
as per operation standard 2 6 84
Next operation : tool damage at bending material in cutting section dia. & thickness

Stopper Position daily equipment check- first piece inspection &

End user: 3 5 90
Disturbed sheet random inspection
No Effect
OEM Assembly: Unable to connect at
Parting Length Ok O/S customer facility 6
Customer Manufacturing Process
preventive maintenance first piece inspection &
:Unable to connect at customer facility Machine condition 3 5 90
check sheet random inspection
Next operation : parts scrap and line stop
2 20 Pipe Cutting

End user: Stopper Position daily equipment check- first piece inspection &
3 5 90
No Effect Disturbed sheet random inspection
OEM Assembly: Unable to connect at
Parting Length Ok U/S customer facility 6
Customer Manufacturing Process
:Unable to connect at customer facility preventive maintenance first piece inspection &
Next operation : parts scrap and line stop Machine condition 3 5 90
check sheet random inspection

End user:
No Effect
No Taper at OEM Assembly: No Effect Multi tube cutting at a random inspection by spl.
Taper Cutting 7 single tube cutting 2 6 84
Cutting Customer Manufacturing Process :No time Gauge
Effect
Next operation : parts scrap

End user:
No Effect
OEM Assembly: No Effect 100% Visual check at
100% Visual check by
3 50 Deburring No Burr Burr Available Customer Manufacturing Process :No 7 Tool Wear out Tool life monitoring 2 7 98 each station by [Link] done
Operator
Effect Operator
Next operation : Fitment NG with mating
part

Ph Value Inadequate Chemical Top-up 2 7 98

Less Washing Time Automation in Machine 2 7 98

4 80 TCE Washing 7
Unclean Water water change daily basis 2 7 98

Improper medium in tank operation standard 2 7 98

 Failure Mode & Effect Analysis Doc. No. EGN/F/DEV/15

(Process FMEA) Date (Org.)

Part Name Pipe Sub Assembly Model YN4 Date (Rev.)
Part No. / Rev. No. 447660-0530 Key Date 17.10.2018 Rev. No.
Customer Name M/s Global Autotech Ltd Dwg. No./Rev. No. 447660-0530, 0
Core Team M.K Jha, Pramod Kumar, K.P Singh
Current Process Controls Action Results

Severity
Op. No.

Class
Potential Failure Potential Cause(s) / Responsibility & target
Step

RPN
Detecti
Occurr
Process Function Requirement Potential Effect(s) of Failure Recommended Action(s)

ence
Action(s)

RPN
Occ
Sev

Det
Mode Mechanism(s) of Failure completion date

on
Prevention Detection
taken

Bent Portion End user: Low cooling

Bent Portion Dia. Dia. Less Than OEM Assembly: Refrigerant flow rate less equipment daily check
Clamping & Die pressure First 5piece inspection by
2/3 of the Original 2/3 of the Customer Manufacturing Process : Part 7 sheet/ 2 5 70
Less vernier caliper
Pipe Dia Original Pipe NG & line stop Setup Approval
Dia Next operation : Part NG & line stop

Bent Portion End user: Refrigerant leakage

Bent Portion Dia. Dia. Less Than OEM Assembly: Refrigerant leakage equipment daily check
Clamping & Die pressure
2/3 of the Original 2/3 of the Customer Manufacturing Process : Part 7 sheet/ 2 First piece inspection 5 70
Less
Pipe Thickness Original Pipe NG & line stop Setup Approval
Thickness Next operation : Part NG & line stop
5 110 CNC Bending

End user: No effect

OEM Assembly: No Effect First 5piece inspection by
Bending Profile Bending Profile equipment daily check
Customer Manufacturing Process : 7 Hydraulic pressure less 2 vernier caliper/ 5 70
OK Not OK sheet
unable to attach with mating part 100% inspection by Gauge
Next operation : Part NG & line stop

Dent ,
End user: No effect 100% Visual check by
Scratch, No 5 Miss-handling No prevention 2 7 70
OEM Assembly: No Effect Operator
Ovality
Appearance Customer Manufacturing Process :
Wrinkle Customer dissatisfaction Wrong Bending Die
Next operation : Part NG & line stop 7 setup approval 2 100% Visual check 7 98
available setting

End user:
No Effect
OEM Assembly: No Effect 100% Visual check at
100% Visual check by
No Burr Burr Available Customer Manufacturing Process :No 7 Tool Wear out Tool life monitoring 2 7 98 each station by [Link] done
Operator
Effect Operator
Next operation : Fitment NG with mating
part
6 140 Sizing

End user: AC Compressor choked &

intermittent operation
OEM Assembly: Refrigerant leakage 100 % SZING MARK random inspection by spl. 5pcs setup every 4
No Ovality Ovality Available 7 SIZING MISS 2 7 98 [Link] done
Customer Manufacturing Process : IMPLIMENT Gauge hour
Leakage
Next operation : Brazing NG

Less Washing Time Automation in Machine 2 7 98

End user: NO Effect
OEM Assembly: No Effect
No Oil Unclean Water water change daily basis 2 100 % visual inspection by 7 98
7 170 TCE Washing Oil Available Customer Manufacturing Process : 7
contamination operator
Customer dissatisfaction
Next operation :Improper Brazing
Improper medium in tank operation standard 2 7 98

PIN HOLE, BLOW

BRAZING
HOLE, BRAZING
CONDITION GAP NOT ALLOWED

FLUX INSIDE THE

Apperance THREAD OF Less Washing Time Automation in Machine 2 7 98
CONNECTOR End user:
No Effect
NO EXCESS OEM Assembly: No Effect
Brazing PREHEATING HEATING 100 % visual inspection by
8 200 Customer Manufacturing Process :No 7 Unclean Water water change daily basis 2 7 98
(447660-0530 CONDITION ALLOWED BY operator
FLAME Effect
Next operation : Fitment NG with mating
part
 Failure Mode & Effect Analysis Doc. No. EGN/F/DEV/15

(Process FMEA) Date (Org.)

Part Name Pipe Sub Assembly Model YN4 Date (Rev.)
Part No. / Rev. No. 447660-0530 Key Date 17.10.2018 Rev. No.
Customer Name M/s Global Autotech Ltd Dwg. No./Rev. No. 447660-0530, 0
Core Team M.K Jha, Pramod Kumar, K.P Singh End user:
No Effect Current Process Controls Action Results

Severity
Op. No.

Potential Failure OEM Assembly: No Effect

Class
Potential Cause(s) / Responsibility & target
Step

RPN
Detecti
Brazing 100 % visual inspection by

Occurr
Process Function Requirement Potential Effect(s) of Failure Recommended Action(s)

ence
Action(s)

RPN
8 200 Customer Manufacturing Process :No 7

Occ
Sev

Det
Mode Mechanism(s) of Failure completion date

on
(447660-0530 Prevention Detection
operator
Effect taken
Next operation : Fitment NG with mating
BRAZING AS PER BRAZING part
FIXTURE.
ORIENTATIO\N

No burn marks, no
Apperance flateness,no leakage Improper medium in tank operation standard 2 7 98

NO EXTRA FLUX ,
NO BURN,NO PIN
HOLE,EXTRA
MATERIAL NOT
ALLOW,WRONG
CHILD PART,No
End user:
burn marks, no No Effect Less Washing Time Automation in Machine 2 7 98
flateness,no leakage OEM Assembly: No Effect
Brazing 100 % visual inspection by
9 230 Appearane Customer Manufacturing Process :No 7
Inspection operator/ Qa engineer
Effect
Next operation : Fitment NG with mating
part Unclean Water water change daily basis 2 7 98
BRAZING FILLET IN
CUT SECTION

Improper medium in tank operation standard 2 7 98

NO
Appearane CONTAMINATION Checking Visual As per standard
End user:
No Effect
OEM Assembly: No Effect
Hot RO Water 100 % visual inspection by
10 260 Appearane Time / Temprature Customer Manufacturing Process :No 7 Less Washing Time Automation in Machine 2 7 98
Cleaning operator/ Qa engineer
Effect
Next operation : Fitment NG with mating
part Qty Dip more than
Appearane Dipping Qty in tank operation standard 2 7 98
standard

Manual inspection Work -Instruction 2 7 98

NO DENT, NO
Appearance SCRATCH,NO
CHIPS Checking gauge Not Checking Gauge
2 7 98
Validate Validation plan

End user: No Effect

operator competency
Profile Not Ok OEM Assembly: No Effect skill level min 2 2 7 98
level
Customer Manufacturing Process: unable
11 290 Final Gauging 7 Pre dispatch inspection
to attach with mating part
Next operation: Part NG & FG Transfer operator competency
Bulging OD U/S or O/S skill level min 2 2 7 98
Stop level

Pin provided in Final

Tube Connector operator competency assy gauge to detect
Not OK skill level min 2 2 7 98 rakesh done 7 2 5 70
Orientation level the wrong tube
connector

Mixing of Parts /
12 320 Packing Packing Ok Wrong Part Customer Dissatisfaction 5 manual inspection packing standard 2 Pre dispatch inspection 7 70
Label

Mo dent, No
End user: No Effect
Appearance scratch, no
OEM Assembly: No Effect
&Critical wrinkle, no extra
13 350 PDI Customer Manufacturing Process: unable to manual inspection As per spec Pre dispatch inspection
Dimensions as edge chips, no
attach with mating part
per IT plan burn mark ,no
Next operation: Part NG & FG Transfer Stop
flateness

Rev Change Description Rev. Date Prepared By Checked By Approved By

 Doc. No.
Failure Mode & Effect Analysis
(Process FMEA) Page No.
Part Name Vehicle / Model Date (Org.)
Part No. / Rev. No. Key Date Date (Rev.)
Customer Name Dwg. No./Rev. No. Rev. No.
Core Team

Occurrence
Current Process Controls Action Results

Detection
Severity
Op. No.

Potential Cause(s) / Responsibility

Class
Potential Failure Potential Effect(s) Recommended

RPN
Description Mechanism(s) of & target
Mode of Failure Action(s)
Failure completion date

Occ
Sev

Det
Prevention Detection Action(s) taken

Format No. 80FM010 Rev. 00 Page 17 of 22

Rev Change Description Rev. Date Prepared By Checked By Approved By

Format No. 80FM010 Rev. 00 Page 18 of 22

sults
RPN

Format No. 80FM010 Rev. 00 Page 19 of 22

d By

Format No. 80FM010 Rev. 00 Page 20 of 22

Sr. No Process Function Appearance
Incoming Inspection
Pipe Cutting
Deburring
Sizing
TCE Washing