PRODUCTION RISK ASSESSMENT

by Failure Mode and Effects Analysis, FMEA

Supplier and site:___Rizvi Fashions Ltd
___________________________________
Rizvi Fashions Ltd. responsible: Nannu Mia Follow up
Assessment Form ______________________________________ assessment
Article name and number:_

(Risk Priority Number)

______________________________
Date:__12_ - 8___ - 2019__

Production Risk
Production Risk

Production Risk

New RPN
Priority level
Severity of
Function/ Production Corrective Resp. Dead-

Occurance

Occ
Detection

Sev
Det
Ref Cause Effect
Process risk/ Action name line
Failure mode

To avoid
such type of
occourance ,
check the
Non conform the uster test
Yarn Incorrect yarn 25.12.
1 Not following spec products & increage 8 7 3 168 report , Rokon 0
Receiving count 19
wastage Internal test
& Cross
check from
other
suppliers .

Yarn Slubby Yarn

2 Receiving Poor Cotton Quality Increage wastage 3 5 3 45 0
Yarn Foreign Fibre
3 Receiving
Yarn
Contaminated Yarn Increage wastage 3 5 3 45 0
Receiving / Child Labour Not follow the Code of
4 Weaving Conduct Production Stop 10 3 3 90 0
Yarn Energy
5 Receiving Reduction Supply shortage Not supply on time 5 5 3 75 0
Yarn Lot Mixing
6 Receiving Poor stock control wastage increase 5 7 3 105 0
Yarn Mix
7 Weaving Poor stock control wastage increase 5 7 3 105
Contamination
8 Weaving Poor Housekeeping wastage increase 3 5 3 45
Width short
9 Weaving less Epi wastage increase 8 7 3 168
Energy
10 Weaving Reduction Supply shortage Not supply on time 5 5 3 75
Lot Mixing
11 Weaving Poor stock control wastage increase 5 7 3 105
Greige GSM or Density Improper
12 Receiving less implementation wastage increase 8 5 3 120
Greige Mix Lots
13 Receiving Poor stock control wastage increase 3 7 3 63
Greige Contamination
14 Receiving Poor Housekeeping Faulty Product 3 7 3 63
Width short
15 Req Width Lack process cont Under size product 5 7 3 105
Energy
16 Energy Reduction Supply shortage Not supply on time 10 3 3 90
More or less PPI
17 Pick
Yarn
Setup Wrong wheel setup More or less GSM 5 7 3 105
package Count Mix
18 feed Poor stock control wastage increase 5 7 3 105
House Contamination
19 keeping Poor Housekeeping Faulty Product 5 7 3 105 Maintain the
Wrong flam
Singing & Hairiness Setting,High Speed,Gas Fabric Fuzzy process
20 Bleaching pressure Low 8 5 3 120 scheme &
match
Improper recipe, production
Color turn into Improper titation, 25.12.
grey improper adjustment of fabric shade variation with Rokon
19
temperature standard in
21 3 5 3 45 every check
Access caustic soda
Improper Wash, points to
High Fabric PH will be in the fabric
22 Improper acid dozing 3 7 3 63 avoid any
shade variation
variation .
Low absorbancy
23 Improper dozing shade change 5 7 3 105
Stenter OBA Process OBA OBA will be in the
24 Finishing Contamination Contaminated fabric fabric 5 3 3 45
Use more binder,Use
Bad Handfeel Fabric Hard
25 less softner 8 3 3 72
Lack of resin After wash size will
Shrinkage fail
26 crosslinking,width short be,Short 8 3 3 72
 Improper machine
Bowing thread bowing
27 control 8 3 3 72
Stitching Bowing cutting Not proper spreeding Uneven Stitch
28 ( Cutting ) 5 3 3 45
Stitching Measurement
29 ( Sewing ) short Wrong cut mark Product reject 5 7 3 105
Stitching alter
30 ( Sewing ) man error Increase rework 5 7 3 105
Stitching OBA Contaminated
31 ( Sewing ) Contamination Poor Housekeeping Product 5 7 3 105
Stitching Metal Contaminated
32 ( Sewing ) Contamination Broken Needle Product 5 7 3 105
Stitching willj label mix Improper Process Increase rework &
33 ( Sewing ) Control rejection 5 7 3 105
Stitching Size Mistake Improper process Increase rework &
34 ( folding ) control rejection 5 7 3 105
Stitching
( Packaging Incorrect label Improper process
35 ) control Customer complaint 5 7 3 105
Stitching
( Packaging Incorrect Improper process
36 ) Packaging control Customer complaint 5 7 3 105
Stitching
( Packaging Metal Improper process
37 ) Contamination control Customer complaint 5 7 3 105
Stitching
( Packaging Product Mixing Improper process
38 ) control Customer complaint 5 7 3 105
Stitching
( Packaging Carton Sealing
39 ) Poor gum tape Increase COPQ 5 7 3 105
Stitching
( Packaging Incorrect Carton Improper process
40 ) used control Increase COPQ 5 3 3 45
If found such
type of
Trims & problem then
poppers might be seggregate all 25.12.
Accessorie Poppers loose Popper attaching error Rokon
opened of loose 19
s
poppers and
41 8 7 3 168 send back to
Final Product Reject
42 Inspection Poor workmanship Product Stop 5 7 3 105
Final Faulty goods
43 Inspection release Poor inspection Customer complaint 5 7 3 105
Warehous
e/ Incorrect Improper process
44 despatch Palletising control Increase COPQ 5 7 3 105
Warehous
e/ Damaged goods Re-pack & Increase
45 despatch
Warehous
Bad handling COPQ 5 7 3 105
e/ Damaged goods Re-pack & Increase
46 despatch
Warehous
Unfit transport COPQ 5 7 3 105
e/ Incorrect load Reject load &
47 despatch quantity Negligence Increase COPQ 5 7 3 105
Warehous
e/ Incorrect load Reject load &
48 despatch quantity Negligence 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