PRODUCTION RISK ASSESSMENT

by Failure Mode and Effects Analysis, FMEA Supplier and site:___Unilliance Textiles Ltd
___________________________________
IKEA responsible: Shawkatul Islam ______________________________________
Article name and number:_ Dvala ______________________________
3. Assessment Form ( page __1_ of _1__ ) Date:__12_ - 8___ - 2012___

(Risk Priority Number)

Follow up
assessment

Production Risk
Production Risk

Production Risk

Priority level
Severity of

Occurance
Detection

RPN
New
Occ
Sev

Det
Function/ Production risk/ Resp.
Ref Process Failure mode Cause Effect Corrective Action name Dead-line

Non conform the products & To avoid such type of occourance , check
Yarn Receiving Incorrect yarn count Not following spec increage wastage the uster test report , Internal test & Cross
1 8 7 3 168 check from other suppliers . Shamim 25.9.12 0

2 Yarn Receiving Slubby Yarn Poor Cotton Quality Increage wastage 3 5 3 45 0

3 Yarn Receiving Foreign Fibre Contaminated Yarn Increage wastage 3 5 3 45 0

4 Yarn Receiving / Weaving Child Labour Not follow the Code of Conduct Production Stop 10 3 3 90 0

5 Yarn Receiving Energy Reduction Supply shortage Not supply on time 5 5 3 75 0

6 Yarn Receiving Lot Mixing Poor stock control wastage increase 5 7 3 105 0

7 Weaving Yarn Mix Poor stock control wastage increase 5 7 3 105

8 Weaving Contamination Poor Housekeeping wastage increase 3 5 3 45

9 Weaving Width short less Epi wastage increase 8 7 3 168

10 Weaving Energy Reduction Supply shortage Not supply on time 5 5 3 75

11 Weaving Lot Mixing Poor stock control wastage increase 5 7 3 105

12 Greige Receiving GSM or Density less Improper implementation wastage increase 8 5 3 120

13 Greige Receiving Mix Lots Poor stock control wastage increase 3 7 3 63

14 Greige Receiving Contamination Poor Housekeeping Faulty Product 3 7 3 63

15 Req Width Width short Lack process cont Under size product 5 7 3 105

16 Energy Energy Reduction Supply shortage Not supply on time 10 3 3 90

17 Pick Setup More or less PPI Wrong wheel setup More or less GSM 5 7 3 105

18 Yarn package feed Count Mix Poor stock control wastage increase 5 7 3 105

19 House keeping Contamination Poor Housekeeping Faulty Product 5 7 3 105

Wrong flam Setting,High
Speed,Gas pressure Low Fabric Fuzzy
20 Singing & Bleaching Hairiness 8 5 3 120
 Improper recipe, Improper Maintain the process scheme & match
Color turn into grey titation, improper adjustment of fabric shade variation production with standard in every check
temperature points to avoid any variation .
21 3 5 3 45 Harun 10.9.12
Improper Wash, Improper acid Access caustic soda will be in the
High Fabric PH dozing fabric shade variation
22 3 7 3 63

23 Low absorbancy Improper dozing shade change 5 7 3 105

Process OBA Contaminated OBA will be in the fabric
24 Stenter Finishing OBA Contamination fabric 5 3 3 45
Bad Handfeel Use more binder,Use less softner Fabric Hard
25 8 3 3 72
Lack of resin crosslinking,width
Shrinkage fail short After wash size will be,Short
26 8 3 3 72
Bowing Improper machine control thread bowing
27 8 3 3 72
Bowing cutting Not proper spreeding Uneven Stitch
28 Stitching ( Cutting ) 5 3 3 45

29 Stitching ( Sewing ) Measurement short Wrong cut mark Product reject 5 7 3 105

30 Stitching ( Sewing ) alter man error Increase rework 5 7 3 105

31 Stitching ( Sewing ) OBA Contamination Poor Housekeeping Contaminated Product 5 7 3 105

32 Stitching ( Sewing ) Metal Contamination Broken Needle Contaminated Product 5 7 3 105

33 Stitching ( Sewing ) willj label mix Improper Process Control Increase rework & rejection 5 7 3 105

34 Stitching ( folding ) Size Mistake Improper process control Increase rework & rejection 5 7 3 105

35 Stitching ( Packaging ) Incorrect label Improper process control Customer complaint 5 7 3 105

36 Stitching ( Packaging ) Incorrect Packaging Improper process control Customer complaint 5 7 3 105

37 Stitching ( Packaging ) Metal Contamination Improper process control Customer complaint 5 7 3 105

38 Stitching ( Packaging ) Product Mixing Improper process control Customer complaint 5 7 3 105

39 Stitching ( Packaging ) Carton Sealing Poor gum tape Increase COPQ 5 7 3 105

40 Stitching ( Packaging ) Incorrect Carton used Improper process control Increase COPQ 5 3 3 45
If found such type of problem then
seggregate all of loose poppers and send
Trims & Accessories Poppers loose Popper attaching error poppers might be opened back to rework to avoid such type of
problem ,Check popper in the inline &
41 8 7 3 168 online as well as conduct pull test Tahseen 17.9.12

42 Final Inspection Product Reject Poor workmanship Product Stop 5 7 3 105

43 Final Inspection Faulty goods release Poor inspection Customer complaint 5 7 3 105

44 Warehouse/despatch Incorrect Palletising Improper process control Increase COPQ 5 7 3 105

45 Warehouse/despatch Damaged goods Bad handling Re-pack & Increase COPQ 5 7 3 105
46 Warehouse/despatch Damaged goods Unfit transport Re-pack & Increase COPQ 5 7 3 105

47 Warehouse/despatch Incorrect load quantity Negligence Reject load & Increase COPQ 5 7 3 105

48 Warehouse/despatch Incorrect load quantity Negligence Reject load & Increase COPQ 5 7 3 105

0 0

0 0

0 0
10 High, 8 Medium, 5 Low, 3 Minor Sev x Det x Occ = RPN. Highest RPN = top priority
9 None, 7 Major, 5 Minor, 3 All
9 High, 6 Medium, 3 Low