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    Part Name.:-Distribution Assy 3P386983-1

    Uploaded by

    Sameer Saxena
    This document is a Process Failure Mode & Effect Analysis (PFMEA) for the distribution assembly process. It identifies potential failure modes at each process step, potential causes, current controls, recommended actions, and risk levels. Some high risk potential failure modes include fitment problems from improper machine settings or tooling, dimensional problems from using the wrong tools, and appearance issues from defects in bending dies. Current controls aim to prevent these failures through first article inspection, tool tracking, operator training, and process monitoring. No additional actions are recommended based on the current risk levels.

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    © All Rights Reserved
    Download as XLS, PDF, TXT or read online from Scribd

    Part Name.:-Distribution Assy 3P386983-1

    Uploaded by

    Sameer Saxena
    65 views50 pages
    This document is a Process Failure Mode & Effect Analysis (PFMEA) for the distribution assembly process. It identifies potential failure modes at each process step, potential causes, current controls, recommended actions, and risk levels. Some high risk potential failure modes include fitment problems from improper machine settings or tooling, dimensional problems from using the wrong tools, and appearance issues from defects in bending dies. Current controls aim to prevent these failures through first article inspection, tool tracking, operator training, and process monitoring. No additional actions are recommended based on the current risk levels.

    Original Description:

    PFMEA

    Original Title

    PFMEA

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    © © All Rights Reserved

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    XLS, PDF, TXT or read online from Scribd

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    This document is a Process Failure Mode & Effect Analysis (PFMEA) for the distribution assembly process. It identifies potential failure modes at each process step, potential causes, current controls, recommended actions, and risk levels. Some high risk potential failure modes include fitment problems from improper machine settings or tooling, dimensional problems from using the wrong tools, and appearance issues from defects in bending dies. Current controls aim to prevent these failures through first article inspection, tool tracking, operator training, and process monitoring. No additional actions are recommended based on the current risk levels.

    Copyright:

    © All Rights Reserved
    Download as XLS, PDF, TXT or read online from Scribd
    Download as xls, pdf, or txt
    65 views50 pages

    Part Name.:-Distribution Assy 3P386983-1

    Uploaded by

    Sameer Saxena
    This document is a Process Failure Mode & Effect Analysis (PFMEA) for the distribution assembly process. It identifies potential failure modes at each process step, potential causes, current controls, recommended actions, and risk levels. Some high risk potential failure modes include fitment problems from improper machine settings or tooling, dimensional problems from using the wrong tools, and appearance issues from defects in bending dies. Current controls aim to prevent these failures through first article inspection, tool tracking, operator training, and process monitoring. No additional actions are recommended based on the current risk levels.

    Copyright:

    © All Rights Reserved
    Download as XLS, PDF, TXT or read online from Scribd
    Download as xls, pdf, or txt
    of 50
    At a glance
    Powered by AI
    The document discusses potential failures, failure effects, occurrence ratings, current controls, detection ratings and risk priority numbers for various process steps in manufacturing distribution assemblies. It aims to conduct a failure mode and effects analysis (FMEA).

    Some of the potential causes of failures mentioned include improper machine setting, defects in cutting dies, wear and tear of tools, improper cleaning, moisture presence in tubes etc.

    Current controls mentioned include machine setup by supervisors, tool history cards, visual inspections, defined solution change frequencies, standard blowing pressures and times etc.

    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/26-09-14

    Part Name.:- Distribution Assy 3P386983-1

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    LENGTH
    FITMENT PROBLEM 10 YC IMPROPER SETTING OF M/C 4 M/C SET UP BY LINE SUPERVISOR 1 40 NOT REQUIRED NA NA
    SHORT/EXCESS
    IMPROPER SETTING OF FIRST OF SAMPLE CHECK SHEET IS
    3 1 30 NOT REQUIRED NA NA
    GUIDE ROLLER IMPLEMENTED.
    CUTTING
    APPERANCE NG
    FIRST OF SAMPLE CHECK SHEET AND
    VISUAL DEFFECT DENTS/SCRATCHES/ 5 YS DEFECTS IN CUTTING M/C DIE 4 2 40 NOT REQUIRED NA NA
    VISUAL INSPECTION IS IMPLEMENTED
    PINCHES
    WEAR & TEAR OF DIE 3 TOOL HISTORY CARD IMPLEMENTED 2 30 NOT REQUIRED NA NA
    EXTERNAL PARTICLES
    IMPROPER CLEANING FIRST OF SAMPLE CHECK SHEET IS
    DEBURRING BRAZING PROBLEM 4 OIL/COPPER CHIPS /GREASE 4 2 32 NOT REQUIRED NA NA
    OF TUBE ENDS IMPLEMENTED
    OUTSIDE THE TUBE.

    FULL/PARTIALLY EXTERNAL PARTICLES


    FIRST OF SAMPLE CHECK SHEET IS
    CHOCKING 5 OIL/COPPER CHIPS /GREASE 3 2 30 NOT REQUIRED NA NA
    IMPLEMENTED
    PROBLEM INSIDE THE TUBE.

    FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    Swazing DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED NA NA
    PARTS IMPARTED
    WEAR & TEAR OF TOOLS 5 TOOL HISTORY CARD IS IMPLEMENTED 2 100 NOT REQUIRED NA NA
    PRESSURE GAUGE DEPLOYED AND
    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED NA NA
    IMPLEMENTED

    FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    BIDDING DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED NA NA
    PARTS IMPARTED

    PRESSURE GAUGE DEPLOYED AND


    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED NA NA
    IMPLEMENTED
    IMPROPER IMPROPER SETTING OF MC & M/C SET UP BY CNC TRAINED OPERATOR
    FITMENT PROBLEM 10 YC 3 2 60 NOT REQUIRED NA NA
    DIMENSIONING FIXTURE & VERIFIED BY PROD SUP

    SPECIFIED MANDREL NOT TRAINING IS IMPARTED & FIRST OF


    3 1 30 NOT REQUIRED NA NA
    MANUAL / USED SAMPLE CHECK SHEET IS IMPLEMENTED
    CNC BENDING
    PROPERLY PLACING OF BENDED PART
    APPERANCE NG
    DENTS/ SCRATCHES/ IMPROPER HANDLING/ INTO TROLLY AS PER STANDARD / FIRST
    DENTS/SCRATCHES/ 5 YS 4 4 80 NOT REQUIRED NA NA
    PINCH DEFECTS IN DIE OFF SAMPLE CHECK SHEET IS
    PINCHES
    IMPLEMENTED

    EXTERNAL PARTICLES TCE SOLUTION CHANGE FREQUENCY IS


    T.C.E.
    IMPROPER CLEANING BRAZING PROBLEM 6 OIL/COPPER CHIPS /GREASE 2 DEFINED AS PER NO.OF PIECES WASHED 2 24 NOT REQUIRED NA NA
    CLEANING
    OUTSIDE THE TUBE. & MONITORING SHEET IS MPLEMENTED

    FULL/PARTIALLY EXTERNAL PARTICLES


    TCE SOLUTION CHANGE FREQUENCY IS
    CHOCKING 6 OIL/COPPER CHIPS /GREASE 2 2 24 NOT REQUIRED NA NA
    DEFINED AS PER NO.OF PIECES WASHED.
    PROBLEM INSIDE THE TUBE.

    IMPROPER COPPER CHIPS/EXTERNAL


    CHOCKING BLOWING PRESSURE STD (5-6 KG/CM2) &
    N2 BLOWING /INSUFFICIENT N2 7 PARTICLES REMAIN INSIDE 3 2 42 NOT REQUIRED NA NA
    PROBLEM TIME (5-10 SEC/PCS ) HAS BEEN SET UP
    FLUSHING TUBE

    MOISTURE PRESENT IN THE BLOWING PRESSURE STD (5-6 KG/CM2) &


    FUCTIONING NOT OK 7 3 2 42 NOT REQUIRED NA NA
    TUBE TIME (5-10 SEC/PCS ) HAS BEEN SET UP

    PROD
    FIXTURE VERIFICATION wrt FINAL
    IMPROPER ALL FIXTURE HAS BEEN MARKED & COLOR SUP FIXTURE VERIFICATION & FIRST OFF
    BRAZING FITMENT PROBLEM 10 YC BRAZING FIXTURE NOT OK 4 4 160 FITMENT JIG TO BE IMPLEMENTED 10 3 3 90
    DIMENSIONING CODED SUDESH/ SAMPLE SHEET IMPLEMENTED
    BEFORE STARTING THE PRODN
    TEJPAL

    ONLY TRAINED OPERATOR TO BE


    PROD ONLY CERTIFIED BRAZER IS ALLOWED
    ONLY SKILLED & SEMISKILLED ALLOWED TO BRAZE & PERIODICALLY
    IMPROPER BRAZING SUP TO BRAZE & BRAZER TRAINING HAS
    LEAKAGE/CHOCKING 10 YC UNTRAINED OPERATOR 4 OPERATORS ARE PERFORMING BRAZING 4 160 TRAINING SYSTEM TO BE 10 3 3 90
    LESS/EXCESS SUDESH/ BEEN IMPARTED TO SEMI SKILLED
    OPERATION. IMPLEMENTED TO SEMI SKILLED OPT
    TEJPAL BRAZER
    TO MAKE THEM TRAINED

    QC
    RED BIN LOCATION MUST BE UNDER RED BIN LOCATION IS DEFINED, ITS
    ENGG/
    SKIPPING OF LEAK PCS & TABLE & LEAKE PORTION TO BE RED USAGE TRAINING HAS BEEN IMPARTED
    LEAK TESTING IMPROPER TESTING GAS LEAKAGE 10 YC 4 RED BIN SYSTEM IS IMPLEMENTED 3 120 SUP 10 3 3 90
    MIXED UP WITH OK PCS MARKED & TRAINING HOW TO USE RED & RED MARKING AT THE LEAK
    MANOJ/
    BIN TO BE IMPARTED PORTION IS IMPLEMENTED
    SANJAY

    STRICTLY RECOMMENDED HIGHLY


    TRAINED OPERATOR TO PERFORM ONLY CERTIFIED LEAKAGE TESTING
    QC
    THIS OPERATION AND PERIODICALLY OPERATOR IS ALLOWED TO TEST &
    ENGG/
    IMPROPER PRESSURE & TRAINING TO THEM & SEMI-SKILLED PERIODICALLY TRAINING IS IMPARTED.
    5 TRAINED OPERATOR APPOINTED 4 200 SUP 10 3 3 90
    TESTING TIME OPERATOR MUST BE IMPARTED & AIR PRESSURE GUAGE IS LOCATED AT
    MANOJ/
    PRESSURE GAUGE MUST BE LOCATED EACH STATION AND MONITORING
    SANJAY
    ON EACH STATION & MONITORING SHEET IS IMPLEMENTED
    MUST BE DONE

    QC
    MINERAL OR RO-WATER TO BE USED ENGG/ RO WATER IS IMPLEMENTED &
    DIRECT TAP WATER IS USED & CHANGE
    CONDITION OF WATER 4 4 160 AND WATER CHANGE FREQUENCY TO SUP CHANGE FREQUENCY IS VISUAL 10 3 3 90
    FREQUENCY IS BASED ON VISUAL
    BE REVIEWED MANOJ/ BASED
    SANJAY

    100% CHOCK TEST TO BE DONE WITH PROD


    CHOCK SKIPPING OF CHOCKED PCS WATER ANOTHER SIDE & MUST BE SUP 100% CHOCK TEST IS IMPLEMENTED
    IMPROPER TESTING GAS FLOW STOP 10 YC 4 NO CHOCK TEST IS PERFORMED 4 160 10 3 3 90
    TESTING & MIXED UP WITH OK PCS CONTROLLED BY CODING/MARKING ON SUDESH/ WITH MARKING
    EACH PART TEJPAL

    IMPROPER
    IMPROPER AIR MOISTURE PRESENT IN THE PRESSURE GUAGE & AIR BLOWING TIME
    WATER DRYING FUNCTIONNING OF 7 3 2 42 NOT REQUIRED NA NA
    BLOWING TUBE PERIOD MAINTAINED
    COMPRESSOR
    MOISTURE PRESENT IN THE DAILY MONITORING PROCESS CHECK
    RUSTING OF TUBES 5 3 2 30 NOT REQUIRED NA NA
    TUBE SHEET HAS BEN IMPLEMENTED.
    IMPROPER PERIODICALLY TRAINING PROVIDED TO ONLY TRAINED OPERATOR MUST
    FINAL FITMENT FITMENT PROBLEM 8 NEGLEGANCY OF OPERATOR 3 3 72 NA NA
    CHECKING/FITMENT OPERATOR. PERFORM THIS PROCESS
    WEAR & TEAR OF FITMENT PERIODICALLY JIG VERIFICATION IS
    3 2 48 NOT REQUIRED NA NA
    ZIG IMPLEMENTED
    PACKING STANDARD IS DISPLAYED AND
    PACKING/ IMPROPER SHORTAGE/EXCESS PACKING NOT DONE AS PER
    10 YC 3 PERIODICALLY BRAINSTORMING IS 2 60 NOT REQUIRED NA NA
    DISPATCH PACKING/DISPATCH OF MATERIAL STANDARD
    IMPARTED
    PACKING STANDARD IS DISPLAYED AND
    WRONG PACKING DONE DUE
    FITMENT PROBLEM 10 YC 4 PERIODICALLY BRAINSTORMING IS 2 80 NOT REQUIRED NA NA
    TO NEGLEGANCY OF OPT
    IMPARTED

    PERIODICALLY BRAINSTORMING OF
    NEGLENGACY OF PACKING
    MIXING PROBLEM 10 YC 4 OPERATORS & REVERIFICATION BY QC 2 80 NOT REQUIRED NA NA
    OPERATOR
    SUP BEFORE DISPATCH

    Page 1 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/26-09-14

    Part Name.:- Distribution Assy 3P386983-1

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    NO ACTION RECOMMENDED IF RPN<100
    ACTION RECOMMENDED IF RPN>=150
    IMMEDIATE ACTION IF RPN>150
    RECOMMENDED
    Prepared By: Checked By: Approved BY:

    Page 2 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/26-09-14

    Part Name.:- Distribution Assy 3P387173-1

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    LENGTH
    FITMENT PROBLEM 10 YC IMPROPER SETTING OF M/C 4 M/C SET UP BY LINE SUPERVISOR 1 40 NOT REQUIRED NA NA
    SHORT/EXCESS
    IMPROPER SETTING OF FIRST OF SAMPLE CHECK SHEET IS
    3 1 30 NOT REQUIRED NA NA
    GUIDE ROLLER IMPLEMENTED.
    CUTTING
    APPERANCE NG
    FIRST OF SAMPLE CHECK SHEET AND
    VISUAL DEFFECT DENTS/SCRATCHES/ 5 YS DEFECTS IN CUTTING M/C DIE 4 2 40 NOT REQUIRED NA NA
    VISUAL INSPECTION IS IMPLEMENTED
    PINCHES
    WEAR & TEAR OF DIE 3 TOOL HISTORY CARD IMPLEMENTED 2 30 NOT REQUIRED NA NA
    EXTERNAL PARTICLES
    IMPROPER CLEANING FIRST OF SAMPLE CHECK SHEET IS
    DEBURRING BRAZING PROBLEM 4 OIL/COPPER CHIPS /GREASE 4 2 32 NOT REQUIRED NA NA
    OF TUBE ENDS IMPLEMENTED
    OUTSIDE THE TUBE.

    FULL/PARTIALLY EXTERNAL PARTICLES


    FIRST OF SAMPLE CHECK SHEET IS
    CHOCKING 5 OIL/COPPER CHIPS /GREASE 3 2 30 NOT REQUIRED NA NA
    IMPLEMENTED
    PROBLEM INSIDE THE TUBE.

    FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    Swazing DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED NA NA
    PARTS IMPARTED
    WEAR & TEAR OF TOOLS 5 TOOL HISTORY CARD IS IMPLEMENTED 2 100 NOT REQUIRED NA NA
    PRESSURE GAUGE DEPLOYED AND
    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED NA NA
    IMPLEMENTED

    FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    BIDDING DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED NA NA
    PARTS IMPARTED

    PRESSURE GAUGE DEPLOYED AND


    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED NA NA
    IMPLEMENTED
    IMPROPER IMPROPER SETTING OF MC & M/C SET UP BY CNC TRAINED OPERATOR
    FITMENT PROBLEM 10 YC 3 2 60 NOT REQUIRED NA NA
    DIMENSIONING FIXTURE & VERIFIED BY PROD SUP

    SPECIFIED MANDREL NOT TRAINING IS IMPARTED & FIRST OF


    3 1 30 NOT REQUIRED NA NA
    MANUAL / USED SAMPLE CHECK SHEET IS IMPLEMENTED
    CNC BENDING
    PROPERLY PLACING OF BENDED PART
    APPERANCE NG
    DENTS/ SCRATCHES/ IMPROPER HANDLING/ INTO TROLLY AS PER STANDARD / FIRST
    DENTS/SCRATCHES/ 5 YS 4 4 80 NOT REQUIRED NA NA
    PINCH DEFECTS IN DIE OFF SAMPLE CHECK SHEET IS
    PINCHES
    IMPLEMENTED

    EXTERNAL PARTICLES TCE SOLUTION CHANGE FREQUENCY IS


    T.C.E.
    IMPROPER CLEANING BRAZING PROBLEM 6 OIL/COPPER CHIPS /GREASE 2 DEFINED AS PER NO.OF PIECES WASHED 2 24 NOT REQUIRED NA NA
    CLEANING
    OUTSIDE THE TUBE. & MONITORING SHEET IS MPLEMENTED

    FULL/PARTIALLY EXTERNAL PARTICLES


    TCE SOLUTION CHANGE FREQUENCY IS
    CHOCKING 6 OIL/COPPER CHIPS /GREASE 2 2 24 NOT REQUIRED NA NA
    DEFINED AS PER NO.OF PIECES WASHED.
    PROBLEM INSIDE THE TUBE.

    IMPROPER COPPER CHIPS/EXTERNAL


    CHOCKING BLOWING PRESSURE STD (5-6 KG/CM2) &
    N2 BLOWING /INSUFFICIENT N2 7 PARTICLES REMAIN INSIDE 3 2 42 NOT REQUIRED NA NA
    PROBLEM TIME (5-10 SEC/PCS ) HAS BEEN SET UP
    FLUSHING TUBE

    MOISTURE PRESENT IN THE BLOWING PRESSURE STD (5-6 KG/CM2) &


    FUCTIONING NOT OK 7 3 2 42 NOT REQUIRED NA NA
    TUBE TIME (5-10 SEC/PCS ) HAS BEEN SET UP

    PROD
    FIXTURE VERIFICATION wrt FINAL
    IMPROPER ALL FIXTURE HAS BEEN MARKED & COLOR SUP FIXTURE VERIFICATION & FIRST OFF
    BRAZING FITMENT PROBLEM 10 YC BRAZING FIXTURE NOT OK 4 4 160 FITMENT JIG TO BE IMPLEMENTED 10 3 3 90
    DIMENSIONING CODED SUDESH/ SAMPLE SHEET IMPLEMENTED
    BEFORE STARTING THE PRODN
    TEJPAL

    ONLY TRAINED OPERATOR TO BE


    PROD ONLY CERTIFIED BRAZER IS ALLOWED
    ONLY SKILLED & SEMISKILLED ALLOWED TO BRAZE & PERIODICALLY
    IMPROPER BRAZING SUP TO BRAZE & BRAZER TRAINING HAS
    LEAKAGE/CHOCKING 10 YC UNTRAINED OPERATOR 4 OPERATORS ARE PERFORMING BRAZING 4 160 TRAINING SYSTEM TO BE 10 3 3 90
    LESS/EXCESS SUDESH/ BEEN IMPARTED TO SEMI SKILLED
    OPERATION. IMPLEMENTED TO SEMI SKILLED OPT
    TEJPAL BRAZER
    TO MAKE THEM TRAINED

    QC
    RED BIN LOCATION MUST BE UNDER RED BIN LOCATION IS DEFINED, ITS
    ENGG/
    SKIPPING OF LEAK PCS & TABLE & LEAKE PORTION TO BE RED USAGE TRAINING HAS BEEN IMPARTED
    LEAK TESTING IMPROPER TESTING GAS LEAKAGE 10 YC 4 RED BIN SYSTEM IS IMPLEMENTED 3 120 SUP 10 3 3 90
    MIXED UP WITH OK PCS MARKED & TRAINING HOW TO USE RED & RED MARKING AT THE LEAK
    MANOJ/
    BIN TO BE IMPARTED PORTION IS IMPLEMENTED
    SANJAY

    STRICTLY RECOMMENDED HIGHLY


    TRAINED OPERATOR TO PERFORM ONLY CERTIFIED LEAKAGE TESTING
    QC
    THIS OPERATION AND PERIODICALLY OPERATOR IS ALLOWED TO TEST &
    ENGG/
    IMPROPER PRESSURE & TRAINING TO THEM & SEMI-SKILLED PERIODICALLY TRAINING IS IMPARTED.
    5 TRAINED OPERATOR APPOINTED 4 200 SUP 10 3 3 90
    TESTING TIME OPERATOR MUST BE IMPARTED & AIR PRESSURE GUAGE IS LOCATED AT
    MANOJ/
    PRESSURE GAUGE MUST BE LOCATED EACH STATION AND MONITORING
    SANJAY
    ON EACH STATION & MONITORING SHEET IS IMPLEMENTED
    MUST BE DONE

    QC
    MINERAL OR RO-WATER TO BE USED ENGG/ RO WATER IS IMPLEMENTED &
    DIRECT TAP WATER IS USED & CHANGE
    CONDITION OF WATER 4 4 160 AND WATER CHANGE FREQUENCY TO SUP CHANGE FREQUENCY IS VISUAL 10 3 3 90
    FREQUENCY IS BASED ON VISUAL
    BE REVIEWED MANOJ/ BASED
    SANJAY

    100% CHOCK TEST TO BE DONE WITH PROD


    CHOCK SKIPPING OF CHOCKED PCS WATER ANOTHER SIDE & MUST BE SUP 100% CHOCK TEST IS IMPLEMENTED
    IMPROPER TESTING GAS FLOW STOP 10 YC 4 NO CHOCK TEST IS PERFORMED 4 160 10 3 3 90
    TESTING & MIXED UP WITH OK PCS CONTROLLED BY CODING/MARKING ON SUDESH/ WITH MARKING
    EACH PART TEJPAL

    IMPROPER
    IMPROPER AIR MOISTURE PRESENT IN THE PRESSURE GUAGE & AIR BLOWING TIME
    WATER DRYING FUNCTIONNING OF 7 3 2 42 NOT REQUIRED NA NA
    BLOWING TUBE PERIOD MAINTAINED
    COMPRESSOR
    MOISTURE PRESENT IN THE DAILY MONITORING PROCESS CHECK
    RUSTING OF TUBES 5 3 2 30 NOT REQUIRED NA NA
    TUBE SHEET HAS BEN IMPLEMENTED.
    IMPROPER PERIODICALLY TRAINING PROVIDED TO ONLY TRAINED OPERATOR MUST
    FINAL FITMENT FITMENT PROBLEM 8 NEGLEGANCY OF OPERATOR 3 3 72 NA NA
    CHECKING/FITMENT OPERATOR. PERFORM THIS PROCESS
    WEAR & TEAR OF FITMENT PERIODICALLY JIG VERIFICATION IS
    3 2 48 NOT REQUIRED NA NA
    ZIG IMPLEMENTED
    PACKING STANDARD IS DISPLAYED AND
    PACKING/ IMPROPER SHORTAGE/EXCESS PACKING NOT DONE AS PER
    10 YC 3 PERIODICALLY BRAINSTORMING IS 2 60 NOT REQUIRED NA NA
    DISPATCH PACKING/DISPATCH OF MATERIAL STANDARD
    IMPARTED
    PACKING STANDARD IS DISPLAYED AND
    WRONG PACKING DONE DUE
    FITMENT PROBLEM 10 YC 4 PERIODICALLY BRAINSTORMING IS 2 80 NOT REQUIRED NA NA
    TO NEGLEGANCY OF OPT
    IMPARTED

    Page 3 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/26-09-14

    Part Name.:- Distribution Assy 3P387173-1

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    PERIODICALLY BRAINSTORMING OF
    NEGLENGACY OF PACKING
    MIXING PROBLEM 10 YC 4 OPERATORS & REVERIFICATION BY QC 2 80 NOT REQUIRED NA NA
    OPERATOR
    SUP BEFORE DISPATCH

    NO ACTION RECOMMENDED IF RPN<100


    ACTION RECOMMENDED IF RPN>=150
    IMMEDIATE ACTION IF RPN>150
    RECOMMENDED
    Prepared By: Checked By: Approved BY:

    Page 4 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/26-09-14

    Part Name.:- Distribution Assy 3P386710-1

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    LENGTH
    FITMENT PROBLEM 10 YC IMPROPER SETTING OF M/C 4 M/C SET UP BY LINE SUPERVISOR 1 40 NOT REQUIRED NA NA
    SHORT/EXCESS
    IMPROPER SETTING OF FIRST OF SAMPLE CHECK SHEET IS
    3 1 30 NOT REQUIRED NA NA
    GUIDE ROLLER IMPLEMENTED.
    CUTTING
    APPERANCE NG
    FIRST OF SAMPLE CHECK SHEET AND
    VISUAL DEFFECT DENTS/SCRATCHES/ 5 YS DEFECTS IN CUTTING M/C DIE 4 2 40 NOT REQUIRED NA NA
    VISUAL INSPECTION IS IMPLEMENTED
    PINCHES
    WEAR & TEAR OF DIE 3 TOOL HISTORY CARD IMPLEMENTED 2 30 NOT REQUIRED NA NA
    EXTERNAL PARTICLES
    IMPROPER CLEANING FIRST OF SAMPLE CHECK SHEET IS
    DEBURRING BRAZING PROBLEM 4 OIL/COPPER CHIPS /GREASE 4 2 32 NOT REQUIRED NA NA
    OF TUBE ENDS IMPLEMENTED
    OUTSIDE THE TUBE.

    FULL/PARTIALLY EXTERNAL PARTICLES


    FIRST OF SAMPLE CHECK SHEET IS
    CHOCKING 5 OIL/COPPER CHIPS /GREASE 3 2 30 NOT REQUIRED NA NA
    IMPLEMENTED
    PROBLEM INSIDE THE TUBE.

    FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    Swazing DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED NA NA
    PARTS IMPARTED
    WEAR & TEAR OF TOOLS 5 TOOL HISTORY CARD IS IMPLEMENTED 2 100 NOT REQUIRED NA NA
    PRESSURE GAUGE DEPLOYED AND
    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED NA NA
    IMPLEMENTED

    FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    Flaring DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED NA NA
    PARTS IMPARTED
    WEAR & TEAR OF TOOLS 5 TOOL HISTORY CARD IS IMPLEMENTED 2 100 NOT REQUIRED NA NA
    PRESSURE GAUGE DEPLOYED AND
    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED NA NA
    IMPLEMENTED

    FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    BIDDING DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED NA NA
    PARTS IMPARTED

    PRESSURE GAUGE DEPLOYED AND


    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED NA NA
    IMPLEMENTED
    IMPROPER IMPROPER SETTING OF MC & M/C SET UP BY CNC TRAINED OPERATOR
    FITMENT PROBLEM 10 YC 3 2 60 NOT REQUIRED NA NA
    DIMENSIONING FIXTURE & VERIFIED BY PROD SUP

    SPECIFIED MANDREL NOT TRAINING IS IMPARTED & FIRST OF


    3 1 30 NOT REQUIRED NA NA
    MANUAL / USED SAMPLE CHECK SHEET IS IMPLEMENTED
    CNC BENDING
    PROPERLY PLACING OF BENDED PART
    APPERANCE NG
    DENTS/ SCRATCHES/ IMPROPER HANDLING/ INTO TROLLY AS PER STANDARD / FIRST
    DENTS/SCRATCHES/ 5 YS 4 4 80 NOT REQUIRED NA NA
    PINCH DEFECTS IN DIE OFF SAMPLE CHECK SHEET IS
    PINCHES
    IMPLEMENTED

    EXTERNAL PARTICLES TCE SOLUTION CHANGE FREQUENCY IS


    T.C.E.
    IMPROPER CLEANING BRAZING PROBLEM 6 OIL/COPPER CHIPS /GREASE 2 DEFINED AS PER NO.OF PIECES WASHED 2 24 NOT REQUIRED NA NA
    CLEANING
    OUTSIDE THE TUBE. & MONITORING SHEET IS MPLEMENTED

    FULL/PARTIALLY EXTERNAL PARTICLES


    TCE SOLUTION CHANGE FREQUENCY IS
    CHOCKING 6 OIL/COPPER CHIPS /GREASE 2 2 24 NOT REQUIRED NA NA
    DEFINED AS PER NO.OF PIECES WASHED.
    PROBLEM INSIDE THE TUBE.

    IMPROPER COPPER CHIPS/EXTERNAL


    CHOCKING BLOWING PRESSURE STD (5-6 KG/CM2) &
    N2 BLOWING /INSUFFICIENT N2 7 PARTICLES REMAIN INSIDE 3 2 42 NOT REQUIRED NA NA
    PROBLEM TIME (5-10 SEC/PCS ) HAS BEEN SET UP
    FLUSHING TUBE

    MOISTURE PRESENT IN THE BLOWING PRESSURE STD (5-6 KG/CM2) &


    FUCTIONING NOT OK 7 3 2 42 NOT REQUIRED NA NA
    TUBE TIME (5-10 SEC/PCS ) HAS BEEN SET UP

    PROD
    FIXTURE VERIFICATION wrt FINAL
    IMPROPER ALL FIXTURE HAS BEEN MARKED & COLOR SUP FIXTURE VERIFICATION & FIRST OFF
    BRAZING FITMENT PROBLEM 10 YC BRAZING FIXTURE NOT OK 4 4 160 FITMENT JIG TO BE IMPLEMENTED 10 3 3 90
    DIMENSIONING CODED SUDESH/ SAMPLE SHEET IMPLEMENTED
    BEFORE STARTING THE PRODN
    TEJPAL

    ONLY TRAINED OPERATOR TO BE


    PROD ONLY CERTIFIED BRAZER IS ALLOWED
    ONLY SKILLED & SEMISKILLED ALLOWED TO BRAZE & PERIODICALLY
    IMPROPER BRAZING SUP TO BRAZE & BRAZER TRAINING HAS
    LEAKAGE/CHOCKING 10 YC UNTRAINED OPERATOR 4 OPERATORS ARE PERFORMING BRAZING 4 160 TRAINING SYSTEM TO BE 10 3 3 90
    LESS/EXCESS SUDESH/ BEEN IMPARTED TO SEMI SKILLED
    OPERATION. IMPLEMENTED TO SEMI SKILLED OPT
    TEJPAL BRAZER
    TO MAKE THEM TRAINED

    QC
    RED BIN LOCATION MUST BE UNDER RED BIN LOCATION IS DEFINED, ITS
    ENGG/
    SKIPPING OF LEAK PCS & TABLE & LEAKE PORTION TO BE RED USAGE TRAINING HAS BEEN IMPARTED
    LEAK TESTING IMPROPER TESTING GAS LEAKAGE 10 YC 4 RED BIN SYSTEM IS IMPLEMENTED 3 120 SUP 10 3 3 90
    MIXED UP WITH OK PCS MARKED & TRAINING HOW TO USE RED & RED MARKING AT THE LEAK
    MANOJ/
    BIN TO BE IMPARTED PORTION IS IMPLEMENTED
    SANJAY

    STRICTLY RECOMMENDED HIGHLY


    TRAINED OPERATOR TO PERFORM ONLY CERTIFIED LEAKAGE TESTING
    QC
    THIS OPERATION AND PERIODICALLY OPERATOR IS ALLOWED TO TEST &
    ENGG/
    IMPROPER PRESSURE & TRAINING TO THEM & SEMI-SKILLED PERIODICALLY TRAINING IS IMPARTED.
    5 TRAINED OPERATOR APPOINTED 4 200 SUP 10 3 3 90
    TESTING TIME OPERATOR MUST BE IMPARTED & AIR PRESSURE GUAGE IS LOCATED AT
    MANOJ/
    PRESSURE GAUGE MUST BE LOCATED EACH STATION AND MONITORING
    SANJAY
    ON EACH STATION & MONITORING SHEET IS IMPLEMENTED
    MUST BE DONE

    QC
    MINERAL OR RO-WATER TO BE USED ENGG/ RO WATER IS IMPLEMENTED &
    DIRECT TAP WATER IS USED & CHANGE
    CONDITION OF WATER 4 4 160 AND WATER CHANGE FREQUENCY TO SUP CHANGE FREQUENCY IS VISUAL 10 3 3 90
    FREQUENCY IS BASED ON VISUAL
    BE REVIEWED MANOJ/ BASED
    SANJAY

    100% CHOCK TEST TO BE DONE WITH PROD


    CHOCK SKIPPING OF CHOCKED PCS WATER ANOTHER SIDE & MUST BE SUP 100% CHOCK TEST IS IMPLEMENTED
    IMPROPER TESTING GAS FLOW STOP 10 YC 4 NO CHOCK TEST IS PERFORMED 4 160 10 3 3 90
    TESTING & MIXED UP WITH OK PCS CONTROLLED BY CODING/MARKING ON SUDESH/ WITH MARKING
    EACH PART TEJPAL

    IMPROPER
    IMPROPER AIR MOISTURE PRESENT IN THE PRESSURE GUAGE & AIR BLOWING TIME
    WATER DRYING FUNCTIONNING OF 7 3 2 42 NOT REQUIRED NA NA
    BLOWING TUBE PERIOD MAINTAINED
    COMPRESSOR
    MOISTURE PRESENT IN THE DAILY MONITORING PROCESS CHECK
    RUSTING OF TUBES 5 3 2 30 NOT REQUIRED NA NA
    TUBE SHEET HAS BEN IMPLEMENTED.
    IMPROPER PERIODICALLY TRAINING PROVIDED TO ONLY TRAINED OPERATOR MUST
    FINAL FITMENT FITMENT PROBLEM 8 NEGLEGANCY OF OPERATOR 3 3 72 NA NA
    CHECKING/FITMENT OPERATOR. PERFORM THIS PROCESS

    Page 5 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/26-09-14

    Part Name.:- Distribution Assy 3P386710-1

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    WEAR & TEAR OF FITMENT PERIODICALLY JIG VERIFICATION IS
    3 2 48 NOT REQUIRED NA NA
    ZIG IMPLEMENTED
    PACKING STANDARD IS DISPLAYED AND
    PACKING/ IMPROPER SHORTAGE/EXCESS PACKING NOT DONE AS PER
    10 YC 3 PERIODICALLY BRAINSTORMING IS 2 60 NOT REQUIRED NA NA
    DISPATCH PACKING/DISPATCH OF MATERIAL STANDARD
    IMPARTED
    PACKING STANDARD IS DISPLAYED AND
    WRONG PACKING DONE DUE
    FITMENT PROBLEM 10 YC 4 PERIODICALLY BRAINSTORMING IS 2 80 NOT REQUIRED NA NA
    TO NEGLEGANCY OF OPT
    IMPARTED

    PERIODICALLY BRAINSTORMING OF
    NEGLENGACY OF PACKING
    MIXING PROBLEM 10 YC 4 OPERATORS & REVERIFICATION BY QC 2 80 NOT REQUIRED NA NA
    OPERATOR
    SUP BEFORE DISPATCH

    NO ACTION RECOMMENDED IF RPN<100


    ACTION RECOMMENDED IF RPN>=150
    IMMEDIATE ACTION IF RPN>150
    RECOMMENDED
    Prepared By: Checked By: Approved BY:

    Page 6 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/26-09-14

    Part Name.:- Distribution Assy 3P387228-1

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    LENGTH
    FITMENT PROBLEM 10 YC IMPROPER SETTING OF M/C 4 M/C SET UP BY LINE SUPERVISOR 1 40 NOT REQUIRED NA NA
    SHORT/EXCESS
    IMPROPER SETTING OF FIRST OF SAMPLE CHECK SHEET IS
    3 1 30 NOT REQUIRED NA NA
    GUIDE ROLLER IMPLEMENTED.
    CUTTING
    APPERANCE NG
    FIRST OF SAMPLE CHECK SHEET AND
    VISUAL DEFFECT DENTS/SCRATCHES/ 5 YS DEFECTS IN CUTTING M/C DIE 4 2 40 NOT REQUIRED NA NA
    VISUAL INSPECTION IS IMPLEMENTED
    PINCHES
    WEAR & TEAR OF DIE 3 TOOL HISTORY CARD IMPLEMENTED 2 30 NOT REQUIRED NA NA
    EXTERNAL PARTICLES
    IMPROPER CLEANING FIRST OF SAMPLE CHECK SHEET IS
    DEBURRING BRAZING PROBLEM 4 OIL/COPPER CHIPS /GREASE 4 2 32 NOT REQUIRED NA NA
    OF TUBE ENDS IMPLEMENTED
    OUTSIDE THE TUBE.

    FULL/PARTIALLY EXTERNAL PARTICLES


    FIRST OF SAMPLE CHECK SHEET IS
    CHOCKING 5 OIL/COPPER CHIPS /GREASE 3 2 30 NOT REQUIRED NA NA
    IMPLEMENTED
    PROBLEM INSIDE THE TUBE.

    FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    Swazing DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED NA NA
    PARTS IMPARTED
    WEAR & TEAR OF TOOLS 5 TOOL HISTORY CARD IS IMPLEMENTED 2 100 NOT REQUIRED NA NA
    PRESSURE GAUGE DEPLOYED AND
    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED NA NA
    IMPLEMENTED

    FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    BIDDING DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED NA NA
    PARTS IMPARTED

    PRESSURE GAUGE DEPLOYED AND


    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED NA NA
    IMPLEMENTED
    IMPROPER IMPROPER SETTING OF MC & M/C SET UP BY CNC TRAINED OPERATOR
    FITMENT PROBLEM 10 YC 3 2 60 NOT REQUIRED NA NA
    DIMENSIONING FIXTURE & VERIFIED BY PROD SUP

    SPECIFIED MANDREL NOT TRAINING IS IMPARTED & FIRST OF


    3 1 30 NOT REQUIRED NA NA
    MANUAL / USED SAMPLE CHECK SHEET IS IMPLEMENTED
    CNC BENDING
    PROPERLY PLACING OF BENDED PART
    APPERANCE NG
    DENTS/ SCRATCHES/ IMPROPER HANDLING/ INTO TROLLY AS PER STANDARD / FIRST
    DENTS/SCRATCHES/ 5 YS 4 4 80 NOT REQUIRED NA NA
    PINCH DEFECTS IN DIE OFF SAMPLE CHECK SHEET IS
    PINCHES
    IMPLEMENTED

    EXTERNAL PARTICLES TCE SOLUTION CHANGE FREQUENCY IS


    T.C.E.
    IMPROPER CLEANING BRAZING PROBLEM 6 OIL/COPPER CHIPS /GREASE 2 DEFINED AS PER NO.OF PIECES WASHED 2 24 NOT REQUIRED NA NA
    CLEANING
    OUTSIDE THE TUBE. & MONITORING SHEET IS MPLEMENTED

    FULL/PARTIALLY EXTERNAL PARTICLES


    TCE SOLUTION CHANGE FREQUENCY IS
    CHOCKING 6 OIL/COPPER CHIPS /GREASE 2 2 24 NOT REQUIRED NA NA
    DEFINED AS PER NO.OF PIECES WASHED.
    PROBLEM INSIDE THE TUBE.

    IMPROPER COPPER CHIPS/EXTERNAL


    CHOCKING BLOWING PRESSURE STD (5-6 KG/CM2) &
    N2 BLOWING /INSUFFICIENT N2 7 PARTICLES REMAIN INSIDE 3 2 42 NOT REQUIRED NA NA
    PROBLEM TIME (5-10 SEC/PCS ) HAS BEEN SET UP
    FLUSHING TUBE

    MOISTURE PRESENT IN THE BLOWING PRESSURE STD (5-6 KG/CM2) &


    FUCTIONING NOT OK 7 3 2 42 NOT REQUIRED NA NA
    TUBE TIME (5-10 SEC/PCS ) HAS BEEN SET UP

    PROD
    FIXTURE VERIFICATION wrt FINAL
    IMPROPER ALL FIXTURE HAS BEEN MARKED & COLOR SUP FIXTURE VERIFICATION & FIRST OFF
    BRAZING FITMENT PROBLEM 10 YC BRAZING FIXTURE NOT OK 4 4 160 FITMENT JIG TO BE IMPLEMENTED 10 3 3 90
    DIMENSIONING CODED SUDESH/ SAMPLE SHEET IMPLEMENTED
    BEFORE STARTING THE PRODN
    TEJPAL

    ONLY TRAINED OPERATOR TO BE


    PROD ONLY CERTIFIED BRAZER IS ALLOWED
    ONLY SKILLED & SEMISKILLED ALLOWED TO BRAZE & PERIODICALLY
    IMPROPER BRAZING SUP TO BRAZE & BRAZER TRAINING HAS
    LEAKAGE/CHOCKING 10 YC UNTRAINED OPERATOR 4 OPERATORS ARE PERFORMING BRAZING 4 160 TRAINING SYSTEM TO BE 10 3 3 90
    LESS/EXCESS SUDESH/ BEEN IMPARTED TO SEMI SKILLED
    OPERATION. IMPLEMENTED TO SEMI SKILLED OPT
    TEJPAL BRAZER
    TO MAKE THEM TRAINED

    QC
    RED BIN LOCATION MUST BE UNDER RED BIN LOCATION IS DEFINED, ITS
    ENGG/
    SKIPPING OF LEAK PCS & TABLE & LEAKE PORTION TO BE RED USAGE TRAINING HAS BEEN IMPARTED
    LEAK TESTING IMPROPER TESTING GAS LEAKAGE 10 YC 4 RED BIN SYSTEM IS IMPLEMENTED 3 120 SUP 10 3 3 90
    MIXED UP WITH OK PCS MARKED & TRAINING HOW TO USE RED & RED MARKING AT THE LEAK
    MANOJ/
    BIN TO BE IMPARTED PORTION IS IMPLEMENTED
    SANJAY

    STRICTLY RECOMMENDED HIGHLY


    TRAINED OPERATOR TO PERFORM ONLY CERTIFIED LEAKAGE TESTING
    QC
    THIS OPERATION AND PERIODICALLY OPERATOR IS ALLOWED TO TEST &
    ENGG/
    IMPROPER PRESSURE & TRAINING TO THEM & SEMI-SKILLED PERIODICALLY TRAINING IS IMPARTED.
    5 TRAINED OPERATOR APPOINTED 4 200 SUP 10 3 3 90
    TESTING TIME OPERATOR MUST BE IMPARTED & AIR PRESSURE GUAGE IS LOCATED AT
    MANOJ/
    PRESSURE GAUGE MUST BE LOCATED EACH STATION AND MONITORING
    SANJAY
    ON EACH STATION & MONITORING SHEET IS IMPLEMENTED
    MUST BE DONE

    QC
    MINERAL OR RO-WATER TO BE USED ENGG/ RO WATER IS IMPLEMENTED &
    DIRECT TAP WATER IS USED & CHANGE
    CONDITION OF WATER 4 4 160 AND WATER CHANGE FREQUENCY TO SUP CHANGE FREQUENCY IS VISUAL 10 3 3 90
    FREQUENCY IS BASED ON VISUAL
    BE REVIEWED MANOJ/ BASED
    SANJAY

    100% CHOCK TEST TO BE DONE WITH PROD


    CHOCK SKIPPING OF CHOCKED PCS WATER ANOTHER SIDE & MUST BE SUP 100% CHOCK TEST IS IMPLEMENTED
    IMPROPER TESTING GAS FLOW STOP 10 YC 4 NO CHOCK TEST IS PERFORMED 4 160 10 3 3 90
    TESTING & MIXED UP WITH OK PCS CONTROLLED BY CODING/MARKING ON SUDESH/ WITH MARKING
    EACH PART TEJPAL

    IMPROPER
    IMPROPER AIR MOISTURE PRESENT IN THE PRESSURE GUAGE & AIR BLOWING TIME
    WATER DRYING FUNCTIONNING OF 7 3 2 42 NOT REQUIRED NA NA
    BLOWING TUBE PERIOD MAINTAINED
    COMPRESSOR
    MOISTURE PRESENT IN THE DAILY MONITORING PROCESS CHECK
    RUSTING OF TUBES 5 3 2 30 NOT REQUIRED NA NA
    TUBE SHEET HAS BEN IMPLEMENTED.
    IMPROPER PERIODICALLY TRAINING PROVIDED TO ONLY TRAINED OPERATOR MUST
    FINAL FITMENT FITMENT PROBLEM 8 NEGLEGANCY OF OPERATOR 3 3 72 NA NA
    CHECKING/FITMENT OPERATOR. PERFORM THIS PROCESS
    WEAR & TEAR OF FITMENT PERIODICALLY JIG VERIFICATION IS
    3 2 48 NOT REQUIRED NA NA
    ZIG IMPLEMENTED
    PACKING STANDARD IS DISPLAYED AND
    PACKING/ IMPROPER SHORTAGE/EXCESS PACKING NOT DONE AS PER
    10 YC 3 PERIODICALLY BRAINSTORMING IS 2 60 NOT REQUIRED NA NA
    DISPATCH PACKING/DISPATCH OF MATERIAL STANDARD
    IMPARTED
    PACKING STANDARD IS DISPLAYED AND
    WRONG PACKING DONE DUE
    FITMENT PROBLEM 10 YC 4 PERIODICALLY BRAINSTORMING IS 2 80 NOT REQUIRED NA NA
    TO NEGLEGANCY OF OPT
    IMPARTED

    Page 7 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/26-09-14

    Part Name.:- Distribution Assy 3P387228-1

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    PERIODICALLY BRAINSTORMING OF
    NEGLENGACY OF PACKING
    MIXING PROBLEM 10 YC 4 OPERATORS & REVERIFICATION BY QC 2 80 NOT REQUIRED NA NA
    OPERATOR
    SUP BEFORE DISPATCH

    NO ACTION RECOMMENDED IF RPN<100


    ACTION RECOMMENDED IF RPN>=150
    IMMEDIATE ACTION IF RPN>150
    RECOMMENDED
    Prepared By: Checked By: Approved BY:

    Page 8 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/26-09-14

    Part Name.:- Distribution Assy 3P387076-1

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    LENGTH
    FITMENT PROBLEM 10 YC IMPROPER SETTING OF M/C 4 M/C SET UP BY LINE SUPERVISOR 1 40 NOT REQUIRED NA NA
    SHORT/EXCESS
    IMPROPER SETTING OF FIRST OF SAMPLE CHECK SHEET IS
    3 1 30 NOT REQUIRED NA NA
    GUIDE ROLLER IMPLEMENTED.
    CUTTING
    APPERANCE NG
    FIRST OF SAMPLE CHECK SHEET AND
    VISUAL DEFFECT DENTS/SCRATCHES/ 5 YS DEFECTS IN CUTTING M/C DIE 4 2 40 NOT REQUIRED NA NA
    VISUAL INSPECTION IS IMPLEMENTED
    PINCHES
    WEAR & TEAR OF DIE 3 TOOL HISTORY CARD IMPLEMENTED 2 30 NOT REQUIRED NA NA
    EXTERNAL PARTICLES
    IMPROPER CLEANING FIRST OF SAMPLE CHECK SHEET IS
    DEBURRING BRAZING PROBLEM 4 OIL/COPPER CHIPS /GREASE 4 2 32 NOT REQUIRED NA NA
    OF TUBE ENDS IMPLEMENTED
    OUTSIDE THE TUBE.

    FULL/PARTIALLY EXTERNAL PARTICLES


    FIRST OF SAMPLE CHECK SHEET IS
    CHOCKING 5 OIL/COPPER CHIPS /GREASE 3 2 30 NOT REQUIRED NA NA
    IMPLEMENTED
    PROBLEM INSIDE THE TUBE.

    FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    Swazing DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED NA NA
    PARTS IMPARTED
    WEAR & TEAR OF TOOLS 5 TOOL HISTORY CARD IS IMPLEMENTED 2 100 NOT REQUIRED NA NA
    PRESSURE GAUGE DEPLOYED AND
    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED NA NA
    IMPLEMENTED

    FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    BIDDING DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED NA NA
    PARTS IMPARTED

    PRESSURE GAUGE DEPLOYED AND


    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED NA NA
    IMPLEMENTED
    IMPROPER IMPROPER SETTING OF MC & M/C SET UP BY CNC TRAINED OPERATOR
    FITMENT PROBLEM 10 YC 3 2 60 NOT REQUIRED NA NA
    DIMENSIONING FIXTURE & VERIFIED BY PROD SUP

    SPECIFIED MANDREL NOT TRAINING IS IMPARTED & FIRST OF


    3 1 30 NOT REQUIRED NA NA
    MANUAL / USED SAMPLE CHECK SHEET IS IMPLEMENTED
    CNC BENDING
    PROPERLY PLACING OF BENDED PART
    APPERANCE NG
    DENTS/ SCRATCHES/ IMPROPER HANDLING/ INTO TROLLY AS PER STANDARD / FIRST
    DENTS/SCRATCHES/ 5 YS 4 4 80 NOT REQUIRED NA NA
    PINCH DEFECTS IN DIE OFF SAMPLE CHECK SHEET IS
    PINCHES
    IMPLEMENTED

    EXTERNAL PARTICLES TCE SOLUTION CHANGE FREQUENCY IS


    T.C.E.
    IMPROPER CLEANING BRAZING PROBLEM 6 OIL/COPPER CHIPS /GREASE 2 DEFINED AS PER NO.OF PIECES WASHED 2 24 NOT REQUIRED NA NA
    CLEANING
    OUTSIDE THE TUBE. & MONITORING SHEET IS MPLEMENTED

    FULL/PARTIALLY EXTERNAL PARTICLES


    TCE SOLUTION CHANGE FREQUENCY IS
    CHOCKING 6 OIL/COPPER CHIPS /GREASE 2 2 24 NOT REQUIRED NA NA
    DEFINED AS PER NO.OF PIECES WASHED.
    PROBLEM INSIDE THE TUBE.

    IMPROPER COPPER CHIPS/EXTERNAL


    CHOCKING BLOWING PRESSURE STD (5-6 KG/CM2) &
    N2 BLOWING /INSUFFICIENT N2 7 PARTICLES REMAIN INSIDE 3 2 42 NOT REQUIRED NA NA
    PROBLEM TIME (5-10 SEC/PCS ) HAS BEEN SET UP
    FLUSHING TUBE

    MOISTURE PRESENT IN THE BLOWING PRESSURE STD (5-6 KG/CM2) &


    FUCTIONING NOT OK 7 3 2 42 NOT REQUIRED NA NA
    TUBE TIME (5-10 SEC/PCS ) HAS BEEN SET UP

    PROD
    FIXTURE VERIFICATION wrt FINAL
    IMPROPER ALL FIXTURE HAS BEEN MARKED & COLOR SUP FIXTURE VERIFICATION & FIRST OFF
    BRAZING FITMENT PROBLEM 10 YC BRAZING FIXTURE NOT OK 4 4 160 FITMENT JIG TO BE IMPLEMENTED 10 3 3 90
    DIMENSIONING CODED SUDESH/ SAMPLE SHEET IMPLEMENTED
    BEFORE STARTING THE PRODN
    TEJPAL

    ONLY TRAINED OPERATOR TO BE


    PROD ONLY CERTIFIED BRAZER IS ALLOWED
    ONLY SKILLED & SEMISKILLED ALLOWED TO BRAZE & PERIODICALLY
    IMPROPER BRAZING SUP TO BRAZE & BRAZER TRAINING HAS
    LEAKAGE/CHOCKING 10 YC UNTRAINED OPERATOR 4 OPERATORS ARE PERFORMING BRAZING 4 160 TRAINING SYSTEM TO BE 10 3 3 90
    LESS/EXCESS SUDESH/ BEEN IMPARTED TO SEMI SKILLED
    OPERATION. IMPLEMENTED TO SEMI SKILLED OPT
    TEJPAL BRAZER
    TO MAKE THEM TRAINED

    QC
    RED BIN LOCATION MUST BE UNDER RED BIN LOCATION IS DEFINED, ITS
    ENGG/
    SKIPPING OF LEAK PCS & TABLE & LEAKE PORTION TO BE RED USAGE TRAINING HAS BEEN IMPARTED
    LEAK TESTING IMPROPER TESTING GAS LEAKAGE 10 YC 4 RED BIN SYSTEM IS IMPLEMENTED 3 120 SUP 10 3 3 90
    MIXED UP WITH OK PCS MARKED & TRAINING HOW TO USE RED & RED MARKING AT THE LEAK
    MANOJ/
    BIN TO BE IMPARTED PORTION IS IMPLEMENTED
    SANJAY

    STRICTLY RECOMMENDED HIGHLY


    TRAINED OPERATOR TO PERFORM ONLY CERTIFIED LEAKAGE TESTING
    QC
    THIS OPERATION AND PERIODICALLY OPERATOR IS ALLOWED TO TEST &
    ENGG/
    IMPROPER PRESSURE & TRAINING TO THEM & SEMI-SKILLED PERIODICALLY TRAINING IS IMPARTED.
    5 TRAINED OPERATOR APPOINTED 4 200 SUP 10 3 3 90
    TESTING TIME OPERATOR MUST BE IMPARTED & AIR PRESSURE GUAGE IS LOCATED AT
    MANOJ/
    PRESSURE GAUGE MUST BE LOCATED EACH STATION AND MONITORING
    SANJAY
    ON EACH STATION & MONITORING SHEET IS IMPLEMENTED
    MUST BE DONE

    QC
    MINERAL OR RO-WATER TO BE USED ENGG/ RO WATER IS IMPLEMENTED &
    DIRECT TAP WATER IS USED & CHANGE
    CONDITION OF WATER 4 4 160 AND WATER CHANGE FREQUENCY TO SUP CHANGE FREQUENCY IS VISUAL 10 3 3 90
    FREQUENCY IS BASED ON VISUAL
    BE REVIEWED MANOJ/ BASED
    SANJAY

    100% CHOCK TEST TO BE DONE WITH PROD


    CHOCK SKIPPING OF CHOCKED PCS WATER ANOTHER SIDE & MUST BE SUP 100% CHOCK TEST IS IMPLEMENTED
    IMPROPER TESTING GAS FLOW STOP 10 YC 4 NO CHOCK TEST IS PERFORMED 4 160 10 3 3 90
    TESTING & MIXED UP WITH OK PCS CONTROLLED BY CODING/MARKING ON SUDESH/ WITH MARKING
    EACH PART TEJPAL

    IMPROPER
    IMPROPER AIR MOISTURE PRESENT IN THE PRESSURE GUAGE & AIR BLOWING TIME
    WATER DRYING FUNCTIONNING OF 7 3 2 42 NOT REQUIRED NA NA
    BLOWING TUBE PERIOD MAINTAINED
    COMPRESSOR
    MOISTURE PRESENT IN THE DAILY MONITORING PROCESS CHECK
    RUSTING OF TUBES 5 3 2 30 NOT REQUIRED NA NA
    TUBE SHEET HAS BEN IMPLEMENTED.
    IMPROPER PERIODICALLY TRAINING PROVIDED TO ONLY TRAINED OPERATOR MUST
    FINAL FITMENT FITMENT PROBLEM 8 NEGLEGANCY OF OPERATOR 3 3 72 NA NA
    CHECKING/FITMENT OPERATOR. PERFORM THIS PROCESS
    WEAR & TEAR OF FITMENT PERIODICALLY JIG VERIFICATION IS
    3 2 48 NOT REQUIRED NA NA
    ZIG IMPLEMENTED
    PACKING STANDARD IS DISPLAYED AND
    PACKING/ IMPROPER SHORTAGE/EXCESS PACKING NOT DONE AS PER
    10 YC 3 PERIODICALLY BRAINSTORMING IS 2 60 NOT REQUIRED NA NA
    DISPATCH PACKING/DISPATCH OF MATERIAL STANDARD
    IMPARTED
    PACKING STANDARD IS DISPLAYED AND
    WRONG PACKING DONE DUE
    FITMENT PROBLEM 10 YC 4 PERIODICALLY BRAINSTORMING IS 2 80 NOT REQUIRED NA NA
    TO NEGLEGANCY OF OPT
    IMPARTED

    Page 9 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/26-09-14

    Part Name.:- Distribution Assy 3P387076-1

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    PERIODICALLY BRAINSTORMING OF
    NEGLENGACY OF PACKING
    MIXING PROBLEM 10 YC 4 OPERATORS & REVERIFICATION BY QC 2 80 NOT REQUIRED NA NA
    OPERATOR
    SUP BEFORE DISPATCH

    NO ACTION RECOMMENDED IF RPN<100


    ACTION RECOMMENDED IF RPN>=150
    IMMEDIATE ACTION IF RPN>150
    RECOMMENDED
    Prepared By: Checked By: Approved BY:

    Page 10 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/26-09-14

    Part Name.:- Capillary Tube - 4P335712-1

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    LENGTH
    FITMENT PROBLEM 10 YC IMPROPER SETTING OF M/C 4 M/C SET UP BY LINE SUPERVISOR 1 40 NOT REQUIRED NA NA
    SHORT/EXCESS
    IMPROPER SETTING OF FIRST OF SAMPLE CHECK SHEET IS
    3 1 30 NOT REQUIRED NA NA
    GUIDE ROLLER IMPLEMENTED.
    CUTTING
    APPERANCE NG
    FIRST OF SAMPLE CHECK SHEET AND
    VISUAL DEFFECT DENTS/SCRATCHES/ 5 YS DEFECTS IN CUTTING M/C DIE 4 2 40 NOT REQUIRED NA NA
    VISUAL INSPECTION IS IMPLEMENTED
    PINCHES
    WEAR & TEAR OF DIE 3 TOOL HISTORY CARD IMPLEMENTED 2 30 NOT REQUIRED NA NA
    EXTERNAL PARTICLES
    IMPROPER CLEANING FIRST OF SAMPLE CHECK SHEET IS
    DEBURRING BRAZING PROBLEM 4 OIL/COPPER CHIPS /GREASE 4 2 32 NOT REQUIRED NA NA
    OF TUBE ENDS IMPLEMENTED
    OUTSIDE THE TUBE.

    FULL/PARTIALLY EXTERNAL PARTICLES


    FIRST OF SAMPLE CHECK SHEET IS
    CHOCKING 5 OIL/COPPER CHIPS /GREASE 3 2 30 NOT REQUIRED NA NA
    IMPLEMENTED
    PROBLEM INSIDE THE TUBE.

    FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    BIDDING DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED NA NA
    PARTS IMPARTED

    PRESSURE GAUGE DEPLOYED AND


    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED NA NA
    IMPLEMENTED

    EXTERNAL PARTICLES TCE SOLUTION CHANGE FREQUENCY IS


    T.C.E.
    IMPROPER CLEANING BRAZING PROBLEM 6 OIL/COPPER CHIPS /GREASE 2 DEFINED AS PER NO.OF PIECES WASHED 2 24 NOT REQUIRED NA NA
    CLEANING
    OUTSIDE THE TUBE. & MONITORING SHEET IS MPLEMENTED

    FULL/PARTIALLY EXTERNAL PARTICLES


    TCE SOLUTION CHANGE FREQUENCY IS
    CHOCKING 6 OIL/COPPER CHIPS /GREASE 2 2 24 NOT REQUIRED NA NA
    DEFINED AS PER NO.OF PIECES WASHED.
    PROBLEM INSIDE THE TUBE.

    IMPROPER COPPER CHIPS/EXTERNAL


    CHOCKING BLOWING PRESSURE STD (5-6 KG/CM2) &
    N2 BLOWING /INSUFFICIENT N2 7 PARTICLES REMAIN INSIDE 3 2 42 NOT REQUIRED NA NA
    PROBLEM TIME (5-10 SEC/PCS ) HAS BEEN SET UP
    FLUSHING TUBE

    MOISTURE PRESENT IN THE BLOWING PRESSURE STD (5-6 KG/CM2) &


    FUCTIONING NOT OK 7 3 2 42 NOT REQUIRED NA NA
    TUBE TIME (5-10 SEC/PCS ) HAS BEEN SET UP

    Flexible Tube LENGTH


    FITMENT PROBLEM 10 YC IMPROPER SETTING OF M/C 4 M/C SET UP BY LINE SUPERVISOR 1 40 NOT REQUIRED NA NA
    Insertion SHORT/EXCESS

    IMPROPER SETTING OF FIRST OF SAMPLE CHECK SHEET IS


    3 1 30 NOT REQUIRED NA NA
    GUIDE ROLLER IMPLEMENTED.

    IMPROPER IMPROPER SETTING OF MC & M/C SET UP BY CNC TRAINED OPERATOR


    FITMENT PROBLEM 10 YC 3 2 60 NOT REQUIRED NA NA
    DIMENSIONING FIXTURE & VERIFIED BY PROD SUP

    SPECIFIED MANDREL NOT TRAINING IS IMPARTED & FIRST OF


    3 1 30 NOT REQUIRED NA NA
    MANUAL / USED SAMPLE CHECK SHEET IS IMPLEMENTED
    CNC BENDING
    PROPERLY PLACING OF BENDED PART
    APPERANCE NG
    DENTS/ SCRATCHES/ IMPROPER HANDLING/ INTO TROLLY AS PER STANDARD / FIRST
    DENTS/SCRATCHES/ 5 YS 4 4 80 NOT REQUIRED NA NA
    PINCH DEFECTS IN DIE OFF SAMPLE CHECK SHEET IS
    PINCHES
    IMPLEMENTED

    100% CHOCK TEST TO BE DONE WITH PROD


    CHOCK SKIPPING OF CHOCKED PCS WATER ANOTHER SIDE & MUST BE SUP 100% CHOCK TEST IS IMPLEMENTED
    IMPROPER TESTING GAS FLOW STOP 10 YC 4 NO CHOCK TEST IS PERFORMED 4 160 10 3 3 90
    TESTING & MIXED UP WITH OK PCS CONTROLLED BY CODING/MARKING ON SUDESH/ WITH MARKING
    EACH PART TEJPAL

    IMPROPER
    IMPROPER AIR MOISTURE PRESENT IN THE PRESSURE GUAGE & AIR BLOWING TIME
    WATER DRYING FUNCTIONNING OF 7 3 2 42 NOT REQUIRED NA NA
    BLOWING TUBE PERIOD MAINTAINED
    COMPRESSOR
    MOISTURE PRESENT IN THE DAILY MONITORING PROCESS CHECK
    RUSTING OF TUBES 5 3 2 30 NOT REQUIRED NA NA
    TUBE SHEET HAS BEN IMPLEMENTED.
    IMPROPER PERIODICALLY TRAINING PROVIDED TO ONLY TRAINED OPERATOR MUST
    FINAL FITMENT FITMENT PROBLEM 8 NEGLEGANCY OF OPERATOR 3 3 72 NA NA
    CHECKING/FITMENT OPERATOR. PERFORM THIS PROCESS
    WEAR & TEAR OF FITMENT PERIODICALLY JIG VERIFICATION IS
    3 2 48 NOT REQUIRED NA NA
    ZIG IMPLEMENTED
    PACKING STANDARD IS DISPLAYED AND
    PACKING/ IMPROPER SHORTAGE/EXCESS PACKING NOT DONE AS PER
    10 YC 3 PERIODICALLY BRAINSTORMING IS 2 60 NOT REQUIRED NA NA
    DISPATCH PACKING/DISPATCH OF MATERIAL STANDARD
    IMPARTED
    PACKING STANDARD IS DISPLAYED AND
    WRONG PACKING DONE DUE
    FITMENT PROBLEM 10 YC 4 PERIODICALLY BRAINSTORMING IS 2 80 NOT REQUIRED NA NA
    TO NEGLEGANCY OF OPT
    IMPARTED

    PERIODICALLY BRAINSTORMING OF
    NEGLENGACY OF PACKING
    MIXING PROBLEM 10 YC 4 OPERATORS & REVERIFICATION BY QC 2 80 NOT REQUIRED NA NA
    OPERATOR
    SUP BEFORE DISPATCH

    NO ACTION RECOMMENDED IF RPN<100


    ACTION RECOMMENDED IF RPN>=150
    IMMEDIATE ACTION IF RPN>150
    RECOMMENDED
    Prepared By: Checked By: Approved BY:

    Page 11 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/26-09-14

    Part Name.:- Capillary Tube - 4P336216-1

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    LENGTH
    FITMENT PROBLEM 10 YC IMPROPER SETTING OF M/C 4 M/C SET UP BY LINE SUPERVISOR 1 40 NOT REQUIRED NA NA
    SHORT/EXCESS
    IMPROPER SETTING OF FIRST OF SAMPLE CHECK SHEET IS
    3 1 30 NOT REQUIRED NA NA
    GUIDE ROLLER IMPLEMENTED.
    CUTTING
    APPERANCE NG
    FIRST OF SAMPLE CHECK SHEET AND
    VISUAL DEFFECT DENTS/SCRATCHES/ 5 YS DEFECTS IN CUTTING M/C DIE 4 2 40 NOT REQUIRED NA NA
    VISUAL INSPECTION IS IMPLEMENTED
    PINCHES
    WEAR & TEAR OF DIE 3 TOOL HISTORY CARD IMPLEMENTED 2 30 NOT REQUIRED NA NA
    EXTERNAL PARTICLES
    IMPROPER CLEANING FIRST OF SAMPLE CHECK SHEET IS
    DEBURRING BRAZING PROBLEM 4 OIL/COPPER CHIPS /GREASE 4 2 32 NOT REQUIRED NA NA
    OF TUBE ENDS IMPLEMENTED
    OUTSIDE THE TUBE.

    FULL/PARTIALLY EXTERNAL PARTICLES


    FIRST OF SAMPLE CHECK SHEET IS
    CHOCKING 5 OIL/COPPER CHIPS /GREASE 3 2 30 NOT REQUIRED NA NA
    IMPLEMENTED
    PROBLEM INSIDE THE TUBE.

    FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    BIDDING DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED NA NA
    PARTS IMPARTED

    PRESSURE GAUGE DEPLOYED AND


    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED NA NA
    IMPLEMENTED

    EXTERNAL PARTICLES TCE SOLUTION CHANGE FREQUENCY IS


    T.C.E.
    IMPROPER CLEANING BRAZING PROBLEM 6 OIL/COPPER CHIPS /GREASE 2 DEFINED AS PER NO.OF PIECES WASHED 2 24 NOT REQUIRED NA NA
    CLEANING
    OUTSIDE THE TUBE. & MONITORING SHEET IS MPLEMENTED

    FULL/PARTIALLY EXTERNAL PARTICLES


    TCE SOLUTION CHANGE FREQUENCY IS
    CHOCKING 6 OIL/COPPER CHIPS /GREASE 2 2 24 NOT REQUIRED NA NA
    DEFINED AS PER NO.OF PIECES WASHED.
    PROBLEM INSIDE THE TUBE.

    IMPROPER COPPER CHIPS/EXTERNAL


    CHOCKING BLOWING PRESSURE STD (5-6 KG/CM2) &
    N2 BLOWING /INSUFFICIENT N2 7 PARTICLES REMAIN INSIDE 3 2 42 NOT REQUIRED NA NA
    PROBLEM TIME (5-10 SEC/PCS ) HAS BEEN SET UP
    FLUSHING TUBE

    MOISTURE PRESENT IN THE BLOWING PRESSURE STD (5-6 KG/CM2) &


    FUCTIONING NOT OK 7 3 2 42 NOT REQUIRED NA NA
    TUBE TIME (5-10 SEC/PCS ) HAS BEEN SET UP

    Flexible Tube LENGTH


    FITMENT PROBLEM 10 YC IMPROPER SETTING OF M/C 4 M/C SET UP BY LINE SUPERVISOR 1 40 NOT REQUIRED NA NA
    Insertion SHORT/EXCESS

    IMPROPER SETTING OF FIRST OF SAMPLE CHECK SHEET IS


    3 1 30 NOT REQUIRED NA NA
    GUIDE ROLLER IMPLEMENTED.

    IMPROPER IMPROPER SETTING OF MC & M/C SET UP BY CNC TRAINED OPERATOR


    FITMENT PROBLEM 10 YC 3 2 60 NOT REQUIRED NA NA
    DIMENSIONING FIXTURE & VERIFIED BY PROD SUP

    SPECIFIED MANDREL NOT TRAINING IS IMPARTED & FIRST OF


    3 1 30 NOT REQUIRED NA NA
    MANUAL / USED SAMPLE CHECK SHEET IS IMPLEMENTED
    CNC BENDING
    PROPERLY PLACING OF BENDED PART
    APPERANCE NG
    DENTS/ SCRATCHES/ IMPROPER HANDLING/ INTO TROLLY AS PER STANDARD / FIRST
    DENTS/SCRATCHES/ 5 YS 4 4 80 NOT REQUIRED NA NA
    PINCH DEFECTS IN DIE OFF SAMPLE CHECK SHEET IS
    PINCHES
    IMPLEMENTED

    100% CHOCK TEST TO BE DONE WITH PROD


    CHOCK SKIPPING OF CHOCKED PCS WATER ANOTHER SIDE & MUST BE SUP 100% CHOCK TEST IS IMPLEMENTED
    IMPROPER TESTING GAS FLOW STOP 10 YC 4 NO CHOCK TEST IS PERFORMED 4 160 10 3 3 90
    TESTING & MIXED UP WITH OK PCS CONTROLLED BY CODING/MARKING ON SUDESH/ WITH MARKING
    EACH PART TEJPAL

    IMPROPER
    IMPROPER AIR MOISTURE PRESENT IN THE PRESSURE GUAGE & AIR BLOWING TIME
    WATER DRYING FUNCTIONNING OF 7 3 2 42 NOT REQUIRED NA NA
    BLOWING TUBE PERIOD MAINTAINED
    COMPRESSOR
    MOISTURE PRESENT IN THE DAILY MONITORING PROCESS CHECK
    RUSTING OF TUBES 5 3 2 30 NOT REQUIRED NA NA
    TUBE SHEET HAS BEN IMPLEMENTED.
    IMPROPER PERIODICALLY TRAINING PROVIDED TO ONLY TRAINED OPERATOR MUST
    FINAL FITMENT FITMENT PROBLEM 8 NEGLEGANCY OF OPERATOR 3 3 72 NA NA
    CHECKING/FITMENT OPERATOR. PERFORM THIS PROCESS
    WEAR & TEAR OF FITMENT PERIODICALLY JIG VERIFICATION IS
    3 2 48 NOT REQUIRED NA NA
    ZIG IMPLEMENTED
    PACKING STANDARD IS DISPLAYED AND
    PACKING/ IMPROPER SHORTAGE/EXCESS PACKING NOT DONE AS PER
    10 YC 3 PERIODICALLY BRAINSTORMING IS 2 60 NOT REQUIRED NA NA
    DISPATCH PACKING/DISPATCH OF MATERIAL STANDARD
    IMPARTED
    PACKING STANDARD IS DISPLAYED AND
    WRONG PACKING DONE DUE
    FITMENT PROBLEM 10 YC 4 PERIODICALLY BRAINSTORMING IS 2 80 NOT REQUIRED NA NA
    TO NEGLEGANCY OF OPT
    IMPARTED

    PERIODICALLY BRAINSTORMING OF
    NEGLENGACY OF PACKING
    MIXING PROBLEM 10 YC 4 OPERATORS & REVERIFICATION BY QC 2 80 NOT REQUIRED NA NA
    OPERATOR
    SUP BEFORE DISPATCH

    NO ACTION RECOMMENDED IF RPN<100


    ACTION RECOMMENDED IF RPN>=150
    IMMEDIATE ACTION IF RPN>150
    RECOMMENDED
    Prepared By: Checked By: Approved BY:

    Page 12 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/14-11-14

    Part Name.:- Capillary tube assy Part Code:-3P386509-1A

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    LENGTH
    FITMENT PROBLEM 10 YC IMPROPER SETTING OF M/C 4 M/C SET UP BY LINE SUPERVISOR 1 40 NOT REQUIRED NA NA
    SHORT/EXCESS
    IMPROPER SETTING OF FIRST OF SAMPLE CHECK SHEET IS
    3 1 30 NOT REQUIRED NA NA
    GUIDE ROLLER IMPLEMENTED.
    CUTTING
    APPERANCE NG
    FIRST OF SAMPLE CHECK SHEET AND
    VISUAL DEFFECT DENTS/SCRATCHES/ 5 YS DEFECTS IN CUTTING M/C DIE 4 2 40 NOT REQUIRED NA NA
    VISUAL INSPECTION IS IMPLEMENTED
    PINCHES
    WEAR & TEAR OF DIE 3 TOOL HISTORY CARD IMPLEMENTED 2 30 NOT REQUIRED NA NA
    EXTERNAL PARTICLES
    IMPROPER CLEANING FIRST OF SAMPLE CHECK SHEET IS
    DEBURRING BRAZING PROBLEM 4 OIL/COPPER CHIPS /GREASE 4 2 32 NOT REQUIRED NA NA
    OF TUBE ENDS IMPLEMENTED
    OUTSIDE THE TUBE.

    FULL/PARTIALLY EXTERNAL PARTICLES


    FIRST OF SAMPLE CHECK SHEET IS
    CHOCKING 5 OIL/COPPER CHIPS /GREASE 3 2 30 NOT REQUIRED NA NA
    IMPLEMENTED
    PROBLEM INSIDE THE TUBE.

    FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    FORMING DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED NA NA
    PARTS IMPARTED
    WEAR & TEAR OF TOOLS 5 TOOL HISTORY CARD IS IMPLEMENTED 2 100 NOT REQUIRED NA NA
    PRESSURE GAUGE DEPLOYED AND
    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED NA NA
    IMPLEMENTED

    FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    BIDDING DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED NA NA
    PARTS IMPARTED

    PRESSURE GAUGE DEPLOYED AND


    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED NA NA
    IMPLEMENTED
    IMPROPER IMPROPER SETTING OF MC & M/C SET UP BY CNC TRAINED OPERATOR
    FITMENT PROBLEM 10 YC 3 2 60 NOT REQUIRED NA NA
    DIMENSIONING FIXTURE & VERIFIED BY PROD SUP

    SPECIFIED MANDREL NOT TRAINING IS IMPARTED & FIRST OF


    3 1 30 NOT REQUIRED NA NA
    MANUAL / USED SAMPLE CHECK SHEET IS IMPLEMENTED
    CNC BENDING
    PROPERLY PLACING OF BENDED PART
    APPERANCE NG
    DENTS/ SCRATCHES/ IMPROPER HANDLING/ INTO TROLLY AS PER STANDARD / FIRST
    DENTS/SCRATCHES/ 5 YS 4 4 80 NOT REQUIRED NA NA
    PINCH DEFECTS IN DIE OFF SAMPLE CHECK SHEET IS
    PINCHES
    IMPLEMENTED

    EXTERNAL PARTICLES TCE SOLUTION CHANGE FREQUENCY IS


    T.C.E.
    IMPROPER CLEANING BRAZING PROBLEM 6 OIL/COPPER CHIPS /GREASE 2 DEFINED AS PER NO.OF PIECES WASHED 2 24 NOT REQUIRED NA NA
    CLEANING
    OUTSIDE THE TUBE. & MONITORING SHEET IS MPLEMENTED

    FULL/PARTIALLY EXTERNAL PARTICLES


    TCE SOLUTION CHANGE FREQUENCY IS
    CHOCKING 6 OIL/COPPER CHIPS /GREASE 2 2 24 NOT REQUIRED NA NA
    DEFINED AS PER NO.OF PIECES WASHED.
    PROBLEM INSIDE THE TUBE.

    IMPROPER COPPER CHIPS/EXTERNAL


    CHOCKING BLOWING PRESSURE STD (5-6 KG/CM2) &
    N2 BLOWING /INSUFFICIENT N2 7 PARTICLES REMAIN INSIDE 3 2 42 NOT REQUIRED NA NA
    PROBLEM TIME (5-10 SEC/PCS ) HAS BEEN SET UP
    FLUSHING TUBE

    MOISTURE PRESENT IN THE BLOWING PRESSURE STD (5-6 KG/CM2) &


    FUCTIONING NOT OK 7 3 2 42 NOT REQUIRED NA NA
    TUBE TIME (5-10 SEC/PCS ) HAS BEEN SET UP

    PROD
    FIXTURE VERIFICATION wrt FINAL
    IMPROPER ALL FIXTURE HAS BEEN MARKED & COLOR SUP FIXTURE VERIFICATION & FIRST OFF
    BRAZING FITMENT PROBLEM 10 YC BRAZING FIXTURE NOT OK 4 4 160 FITMENT JIG TO BE IMPLEMENTED 10 3 3 90
    DIMENSIONING CODED SUDESH/ SAMPLE SHEET IMPLEMENTED
    BEFORE STARTING THE PRODN
    TEJPAL

    ONLY TRAINED OPERATOR TO BE


    PROD ONLY CERTIFIED BRAZER IS ALLOWED
    ONLY SKILLED & SEMISKILLED ALLOWED TO BRAZE & PERIODICALLY
    IMPROPER BRAZING SUP TO BRAZE & BRAZER TRAINING HAS
    LEAKAGE/CHOCKING 10 YC UNTRAINED OPERATOR 4 OPERATORS ARE PERFORMING BRAZING 4 160 TRAINING SYSTEM TO BE 10 3 3 90
    LESS/EXCESS SUDESH/ BEEN IMPARTED TO SEMI SKILLED
    OPERATION. IMPLEMENTED TO SEMI SKILLED OPT
    TEJPAL BRAZER
    TO MAKE THEM TRAINED

    QC
    RED BIN LOCATION MUST BE UNDER RED BIN LOCATION IS DEFINED, ITS
    ENGG/
    SKIPPING OF LEAK PCS & TABLE & LEAKE PORTION TO BE RED USAGE TRAINING HAS BEEN IMPARTED
    LEAK TESTING IMPROPER TESTING GAS LEAKAGE 10 YC 4 RED BIN SYSTEM IS IMPLEMENTED 3 120 SUP 10 3 3 90
    MIXED UP WITH OK PCS MARKED & TRAINING HOW TO USE RED & RED MARKING AT THE LEAK
    MANOJ/
    BIN TO BE IMPARTED PORTION IS IMPLEMENTED
    SANJAY

    STRICTLY RECOMMENDED HIGHLY


    TRAINED OPERATOR TO PERFORM ONLY CERTIFIED LEAKAGE TESTING
    QC
    THIS OPERATION AND PERIODICALLY OPERATOR IS ALLOWED TO TEST &
    ENGG/
    IMPROPER PRESSURE & TRAINING TO THEM & SEMI-SKILLED PERIODICALLY TRAINING IS IMPARTED.
    5 TRAINED OPERATOR APPOINTED 4 200 SUP 10 3 3 90
    TESTING TIME OPERATOR MUST BE IMPARTED & AIR PRESSURE GUAGE IS LOCATED AT
    MANOJ/
    PRESSURE GAUGE MUST BE LOCATED EACH STATION AND MONITORING
    SANJAY
    ON EACH STATION & MONITORING SHEET IS IMPLEMENTED
    MUST BE DONE

    QC
    MINERAL OR RO-WATER TO BE USED ENGG/ RO WATER IS IMPLEMENTED &
    DIRECT TAP WATER IS USED & CHANGE
    CONDITION OF WATER 4 4 160 AND WATER CHANGE FREQUENCY TO SUP CHANGE FREQUENCY IS VISUAL 10 3 3 90
    FREQUENCY IS BASED ON VISUAL
    BE REVIEWED MANOJ/ BASED
    SANJAY

    100% CHOCK TEST TO BE DONE WITH PROD


    CHOCK SKIPPING OF CHOCKED PCS WATER ANOTHER SIDE & MUST BE SUP 100% CHOCK TEST IS IMPLEMENTED
    IMPROPER TESTING GAS FLOW STOP 10 YC 4 NO CHOCK TEST IS PERFORMED 4 160 10 3 3 90
    TESTING & MIXED UP WITH OK PCS CONTROLLED BY CODING/MARKING ON SUDESH/ WITH MARKING
    EACH PART TEJPAL

    IMPROPER
    IMPROPER AIR MOISTURE PRESENT IN THE PRESSURE GUAGE & AIR BLOWING TIME
    WATER DRYING FUNCTIONNING OF 7 3 2 42 NOT REQUIRED NA NA
    BLOWING TUBE PERIOD MAINTAINED
    COMPRESSOR
    MOISTURE PRESENT IN THE DAILY MONITORING PROCESS CHECK
    RUSTING OF TUBES 5 3 2 30 NOT REQUIRED NA NA
    TUBE SHEET HAS BEN IMPLEMENTED.
    IMPROPER PERIODICALLY TRAINING PROVIDED TO ONLY TRAINED OPERATOR MUST
    FINAL FITMENT FITMENT PROBLEM 8 NEGLEGANCY OF OPERATOR 3 3 72 NA NA
    CHECKING/FITMENT OPERATOR. PERFORM THIS PROCESS
    WEAR & TEAR OF FITMENT PERIODICALLY JIG VERIFICATION IS
    3 2 48 NOT REQUIRED NA NA
    ZIG IMPLEMENTED
    PACKING STANDARD IS DISPLAYED AND
    PACKING/ IMPROPER SHORTAGE/EXCESS PACKING NOT DONE AS PER
    10 YC 3 PERIODICALLY BRAINSTORMING IS 2 60 NOT REQUIRED NA NA
    DISPATCH PACKING/DISPATCH OF MATERIAL STANDARD
    IMPARTED
    PACKING STANDARD IS DISPLAYED AND
    WRONG PACKING DONE DUE
    FITMENT PROBLEM 10 YC 4 PERIODICALLY BRAINSTORMING IS 2 80 NOT REQUIRED NA NA
    TO NEGLEGANCY OF OPT
    IMPARTED

    Page 13 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/14-11-14

    Part Name.:- Capillary tube assy Part Code:-3P386509-1A

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    PERIODICALLY BRAINSTORMING OF
    NEGLENGACY OF PACKING
    MIXING PROBLEM 10 YC 4 OPERATORS & REVERIFICATION BY QC 2 80 NOT REQUIRED NA NA
    OPERATOR
    SUP BEFORE DISPATCH

    NO ACTION RECOMMENDED IF RPN<100


    ACTION RECOMMENDED IF RPN>=150
    IMMEDIATE ACTION IF RPN>150
    RECOMMENDED
    Prepared By: Checked By: Approved BY:

    Page 14 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/26-09-14

    Part Name-Feeler bulb mounting pipe 4PA17856-6J

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    LENGTH
    FITMENT PROBLEM 10 YC IMPROPER SETTING OF M/C 4 M/C SET UP BY LINE SUPERVISOR 1 40 NOT REQUIRED NA NA
    SHORT/EXCESS
    IMPROPER SETTING OF FIRST OF SAMPLE CHECK SHEET IS
    3 1 30 NOT REQUIRED NA NA
    GUIDE ROLLER IMPLEMENTED.
    CUTTING
    APPERANCE NG
    FIRST OF SAMPLE CHECK SHEET AND
    VISUAL DEFFECT DENTS/SCRATCHES/ 5 YS DEFECTS IN CUTTING M/C DIE 4 2 40 NOT REQUIRED NA NA
    VISUAL INSPECTION IS IMPLEMENTED
    PINCHES
    WEAR & TEAR OF DIE 3 TOOL HISTORY CARD IMPLEMENTED 2 30 NOT REQUIRED NA NA
    EXTERNAL PARTICLES
    IMPROPER CLEANING FIRST OF SAMPLE CHECK SHEET IS
    DEBURRING BRAZING PROBLEM 4 OIL/COPPER CHIPS /GREASE 4 2 32 NOT REQUIRED NA NA
    OF TUBE ENDS IMPLEMENTED
    OUTSIDE THE TUBE.

    FULL/PARTIALLY EXTERNAL PARTICLES


    FIRST OF SAMPLE CHECK SHEET IS
    CHOCKING 5 OIL/COPPER CHIPS /GREASE 3 2 30 NOT REQUIRED NA NA
    IMPLEMENTED
    PROBLEM INSIDE THE TUBE.

    EXTERNAL PARTICLES TCE SOLUTION CHANGE FREQUENCY IS


    T.C.E.
    IMPROPER CLEANING BRAZING PROBLEM 6 OIL/COPPER CHIPS /GREASE 2 DEFINED AS PER NO.OF PIECES WASHED 2 24 NOT REQUIRED NA NA
    CLEANING
    OUTSIDE THE TUBE. & MONITORING SHEET IS MPLEMENTED

    FULL/PARTIALLY EXTERNAL PARTICLES


    TCE SOLUTION CHANGE FREQUENCY IS
    CHOCKING 6 OIL/COPPER CHIPS /GREASE 2 2 24 NOT REQUIRED NA NA
    DEFINED AS PER NO.OF PIECES WASHED.
    PROBLEM INSIDE THE TUBE.

    IMPROPER COPPER CHIPS/EXTERNAL


    CHOCKING BLOWING PRESSURE STD (5-6 KG/CM2) &
    N2 BLOWING /INSUFFICIENT N2 7 PARTICLES REMAIN INSIDE 3 2 42 NOT REQUIRED NA NA
    PROBLEM TIME (5-10 SEC/PCS ) HAS BEEN SET UP
    FLUSHING TUBE

    MOISTURE PRESENT IN THE BLOWING PRESSURE STD (5-6 KG/CM2) &


    FUCTIONING NOT OK 7 3 2 42 NOT REQUIRED NA NA
    TUBE TIME (5-10 SEC/PCS ) HAS BEEN SET UP

    IMPROPER
    IMPROPER AIR MOISTURE PRESENT IN THE PRESSURE GUAGE & AIR BLOWING TIME
    WATER DRYING FUNCTIONNING OF 7 3 2 42 NOT REQUIRED NA NA
    BLOWING TUBE PERIOD MAINTAINED
    COMPRESSOR
    MOISTURE PRESENT IN THE DAILY MONITORING PROCESS CHECK
    RUSTING OF TUBES 5 3 2 30 NOT REQUIRED NA NA
    TUBE SHEET HAS BEN IMPLEMENTED.
    IMPROPER PERIODICALLY TRAINING PROVIDED TO ONLY TRAINED OPERATOR MUST
    FINAL FITMENT FITMENT PROBLEM 8 NEGLEGANCY OF OPERATOR 3 3 72 NA NA
    CHECKING/FITMENT OPERATOR. PERFORM THIS PROCESS
    WEAR & TEAR OF FITMENT PERIODICALLY JIG VERIFICATION IS
    3 2 48 NOT REQUIRED NA NA
    ZIG IMPLEMENTED
    PACKING STANDARD IS DISPLAYED AND
    PACKING/ IMPROPER SHORTAGE/EXCESS PACKING NOT DONE AS PER
    10 YC 3 PERIODICALLY BRAINSTORMING IS 2 60 NOT REQUIRED NA NA
    DISPATCH PACKING/DISPATCH OF MATERIAL STANDARD
    IMPARTED
    PACKING STANDARD IS DISPLAYED AND
    WRONG PACKING DONE DUE
    FITMENT PROBLEM 10 YC 4 PERIODICALLY BRAINSTORMING IS 2 80 NOT REQUIRED NA NA
    TO NEGLEGANCY OF OPT
    IMPARTED

    PERIODICALLY BRAINSTORMING OF
    NEGLENGACY OF PACKING
    MIXING PROBLEM 10 YC 4 OPERATORS & REVERIFICATION BY QC 2 80 NOT REQUIRED NA NA
    OPERATOR
    SUP BEFORE DISPATCH

    NO ACTION RECOMMENDED IF RPN<100


    ACTION RECOMMENDED IF RPN>=150
    IMMEDIATE ACTION IF RPN>150
    RECOMMENDED
    Prepared By: Checked By: Approved BY:

    Page 15 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/25-11-14

    Part name-Suction pipe assy Part Code-3P382071-1A

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    LENGTH
    FITMENT PROBLEM 10 YC IMPROPER SETTING OF M/C 4 M/C SET UP BY LINE SUPERVISOR 1 40 NOT REQUIRED NA NA
    SHORT/EXCESS
    IMPROPER SETTING OF FIRST OF SAMPLE CHECK SHEET IS
    3 1 30 NOT REQUIRED NA NA
    GUIDE ROLLER IMPLEMENTED.
    CUTTING
    APPERANCE NG
    FIRST OF SAMPLE CHECK SHEET AND
    VISUAL DEFFECT DENTS/SCRATCHES/ 5 YS DEFECTS IN CUTTING M/C DIE 4 2 40 NOT REQUIRED NA NA
    VISUAL INSPECTION IS IMPLEMENTED
    PINCHES
    WEAR & TEAR OF DIE 3 TOOL HISTORY CARD IMPLEMENTED 2 30 NOT REQUIRED NA NA
    EXTERNAL PARTICLES
    IMPROPER CLEANING FIRST OF SAMPLE CHECK SHEET IS
    DEBURRING BRAZING PROBLEM 4 OIL/COPPER CHIPS /GREASE 4 2 32 NOT REQUIRED NA NA
    OF TUBE ENDS IMPLEMENTED
    OUTSIDE THE TUBE.

    FULL/PARTIALLY EXTERNAL PARTICLES


    FIRST OF SAMPLE CHECK SHEET IS
    CHOCKING 5 OIL/COPPER CHIPS /GREASE 3 2 30 NOT REQUIRED NA NA
    IMPLEMENTED
    PROBLEM INSIDE THE TUBE.

    FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    FORMING DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED NA NA
    PARTS IMPARTED
    WEAR & TEAR OF TOOLS 5 TOOL HISTORY CARD IS IMPLEMENTED 2 100 NOT REQUIRED NA NA
    PRESSURE GAUGE DEPLOYED AND
    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED NA NA
    IMPLEMENTED
    IMPROPER IMPROPER SETTING OF MC & M/C SET UP BY CNC TRAINED OPERATOR
    FITMENT PROBLEM 10 YC 3 2 60 NOT REQUIRED NA NA
    DIMENSIONING FIXTURE & VERIFIED BY PROD SUP

    SPECIFIED MANDREL NOT TRAINING IS IMPARTED & FIRST OF


    3 1 30 NOT REQUIRED NA NA
    MANUAL / USED SAMPLE CHECK SHEET IS IMPLEMENTED
    CNC BENDING
    PROPERLY PLACING OF BENDED PART
    APPERANCE NG
    DENTS/ SCRATCHES/ IMPROPER HANDLING/ INTO TROLLY AS PER STANDARD / FIRST
    DENTS/SCRATCHES/ 5 YS 4 4 80 NOT REQUIRED NA NA
    PINCH DEFECTS IN DIE OFF SAMPLE CHECK SHEET IS
    PINCHES
    IMPLEMENTED

    EXTERNAL PARTICLES TCE SOLUTION CHANGE FREQUENCY IS


    T.C.E.
    IMPROPER CLEANING BRAZING PROBLEM 6 OIL/COPPER CHIPS /GREASE 2 DEFINED AS PER NO.OF PIECES WASHED 2 24 NOT REQUIRED NA NA
    CLEANING
    OUTSIDE THE TUBE. & MONITORING SHEET IS MPLEMENTED

    FULL/PARTIALLY EXTERNAL PARTICLES


    TCE SOLUTION CHANGE FREQUENCY IS
    CHOCKING 6 OIL/COPPER CHIPS /GREASE 2 2 24 NOT REQUIRED NA NA
    DEFINED AS PER NO.OF PIECES WASHED.
    PROBLEM INSIDE THE TUBE.

    IMPROPER COPPER CHIPS/EXTERNAL


    CHOCKING BLOWING PRESSURE STD (5-6 KG/CM2) &
    N2 BLOWING /INSUFFICIENT N2 7 PARTICLES REMAIN INSIDE 3 2 42 NOT REQUIRED NA NA
    PROBLEM TIME (5-10 SEC/PCS ) HAS BEEN SET UP
    FLUSHING TUBE

    MOISTURE PRESENT IN THE BLOWING PRESSURE STD (5-6 KG/CM2) &


    FUCTIONING NOT OK 7 3 2 42 NOT REQUIRED NA NA
    TUBE TIME (5-10 SEC/PCS ) HAS BEEN SET UP

    PROD
    FIXTURE VERIFICATION wrt FINAL
    IMPROPER ALL FIXTURE HAS BEEN MARKED & COLOR SUP FIXTURE VERIFICATION & FIRST OFF
    BRAZING FITMENT PROBLEM 10 YC BRAZING FIXTURE NOT OK 4 4 160 FITMENT JIG TO BE IMPLEMENTED 10 3 3 90
    DIMENSIONING CODED SUDESH/ SAMPLE SHEET IMPLEMENTED
    BEFORE STARTING THE PRODN
    TEJPAL

    ONLY TRAINED OPERATOR TO BE


    PROD ONLY CERTIFIED BRAZER IS ALLOWED
    ONLY SKILLED & SEMISKILLED ALLOWED TO BRAZE & PERIODICALLY
    IMPROPER BRAZING SUP TO BRAZE & BRAZER TRAINING HAS
    LEAKAGE/CHOCKING 10 YC UNTRAINED OPERATOR 4 OPERATORS ARE PERFORMING BRAZING 4 160 TRAINING SYSTEM TO BE 10 3 3 90
    LESS/EXCESS SUDESH/ BEEN IMPARTED TO SEMI SKILLED
    OPERATION. IMPLEMENTED TO SEMI SKILLED OPT
    TEJPAL BRAZER
    TO MAKE THEM TRAINED

    QC
    RED BIN LOCATION MUST BE UNDER RED BIN LOCATION IS DEFINED, ITS
    ENGG/
    SKIPPING OF LEAK PCS & TABLE & LEAKE PORTION TO BE RED USAGE TRAINING HAS BEEN IMPARTED
    LEAK TESTING IMPROPER TESTING GAS LEAKAGE 10 YC 4 RED BIN SYSTEM IS IMPLEMENTED 3 120 SUP 10 3 3 90
    MIXED UP WITH OK PCS MARKED & TRAINING HOW TO USE RED & RED MARKING AT THE LEAK
    MANOJ/
    BIN TO BE IMPARTED PORTION IS IMPLEMENTED
    SANJAY

    STRICTLY RECOMMENDED HIGHLY


    TRAINED OPERATOR TO PERFORM ONLY CERTIFIED LEAKAGE TESTING
    QC
    THIS OPERATION AND PERIODICALLY OPERATOR IS ALLOWED TO TEST &
    ENGG/
    IMPROPER PRESSURE & TRAINING TO THEM & SEMI-SKILLED PERIODICALLY TRAINING IS IMPARTED.
    5 TRAINED OPERATOR APPOINTED 4 200 SUP 10 3 3 90
    TESTING TIME OPERATOR MUST BE IMPARTED & AIR PRESSURE GUAGE IS LOCATED AT
    MANOJ/
    PRESSURE GAUGE MUST BE LOCATED EACH STATION AND MONITORING
    SANJAY
    ON EACH STATION & MONITORING SHEET IS IMPLEMENTED
    MUST BE DONE

    QC
    MINERAL OR RO-WATER TO BE USED ENGG/ RO WATER IS IMPLEMENTED &
    DIRECT TAP WATER IS USED & CHANGE
    CONDITION OF WATER 4 4 160 AND WATER CHANGE FREQUENCY TO SUP CHANGE FREQUENCY IS VISUAL 10 3 3 90
    FREQUENCY IS BASED ON VISUAL
    BE REVIEWED MANOJ/ BASED
    SANJAY

    100% CHOCK TEST TO BE DONE WITH PROD


    CHOCK SKIPPING OF CHOCKED PCS WATER ANOTHER SIDE & MUST BE SUP 100% CHOCK TEST IS IMPLEMENTED
    IMPROPER TESTING GAS FLOW STOP 10 YC 4 NO CHOCK TEST IS PERFORMED 4 160 10 3 3 90
    TESTING & MIXED UP WITH OK PCS CONTROLLED BY CODING/MARKING ON SUDESH/ WITH MARKING
    EACH PART TEJPAL

    IMPROPER
    IMPROPER AIR MOISTURE PRESENT IN THE PRESSURE GUAGE & AIR BLOWING TIME
    WATER DRYING FUNCTIONNING OF 7 3 2 42 NOT REQUIRED NA NA
    BLOWING TUBE PERIOD MAINTAINED
    COMPRESSOR
    MOISTURE PRESENT IN THE DAILY MONITORING PROCESS CHECK
    RUSTING OF TUBES 5 3 2 30 NOT REQUIRED NA NA
    TUBE SHEET HAS BEN IMPLEMENTED.
    IMPROPER PERIODICALLY TRAINING PROVIDED TO ONLY TRAINED OPERATOR MUST
    FINAL FITMENT FITMENT PROBLEM 8 NEGLEGANCY OF OPERATOR 3 3 72 NA NA
    CHECKING/FITMENT OPERATOR. PERFORM THIS PROCESS
    WEAR & TEAR OF FITMENT PERIODICALLY JIG VERIFICATION IS
    3 2 48 NOT REQUIRED NA NA
    ZIG IMPLEMENTED
    PACKING STANDARD IS DISPLAYED AND
    PACKING/ IMPROPER SHORTAGE/EXCESS PACKING NOT DONE AS PER
    10 YC 3 PERIODICALLY BRAINSTORMING IS 2 60 NOT REQUIRED NA NA
    DISPATCH PACKING/DISPATCH OF MATERIAL STANDARD
    IMPARTED

    PACKING STANDARD IS DISPLAYED AND


    WRONG PACKING DONE DUE
    FITMENT PROBLEM 10 YC 4 PERIODICALLY BRAINSTORMING IS 2 80 NOT REQUIRED NA NA
    TO NEGLEGANCY OF OPT
    IMPARTED

    PERIODICALLY BRAINSTORMING OF
    NEGLENGACY OF PACKING
    MIXING PROBLEM 10 YC 4 OPERATORS & REVERIFICATION BY QC 2 80 NOT REQUIRED NA NA
    OPERATOR
    SUP BEFORE DISPATCH

    NO ACTION RECOMMENDED IF RPN<100


    ACTION RECOMMENDED IF RPN>=150
    IMMEDIATE ACTION IF RPN>150
    RECOMMENDED

    Page 16 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/25-11-14

    Part name-Suction pipe assy Part Code-3P382071-1A

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    Prepared By: Checked By: Approved BY:

    Page 17 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/25-11-14
    Part name-Suction pipe Part Code-3P386544-1

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN

    RISK PN
    STEP/INPUT MODE EFFECTS

    CLASS
    LENGTH
    FITMENT PROBLEM 10 YC IMPROPER SETTING OF M/C 4 M/C SET UP BY LINE SUPERVISOR 1 40 NOT REQUIRED NA NA
    SHORT/EXCESS
    IMPROPER SETTING OF FIRST OF SAMPLE CHECK SHEET IS
    3 1 30 NOT REQUIRED NA NA
    GUIDE ROLLER IMPLEMENTED.
    CUTTING
    APPERANCE NG
    FIRST OF SAMPLE CHECK SHEET AND
    VISUAL DEFFECT DENTS/SCRATCHES/ 5 YS DEFECTS IN CUTTING M/C DIE 4 2 40 NOT REQUIRED NA NA
    VISUAL INSPECTION IS IMPLEMENTED
    PINCHES
    WEAR & TEAR OF DIE 3 TOOL HISTORY CARD IMPLEMENTED 2 30 NOT REQUIRED NA NA
    EXTERNAL PARTICLES
    IMPROPER CLEANING FIRST OF SAMPLE CHECK SHEET IS
    DEBURRING BRAZING PROBLEM 4 OIL/COPPER CHIPS /GREASE 4 2 32 NOT REQUIRED NA NA
    OF TUBE ENDS IMPLEMENTED
    OUTSIDE THE TUBE.

    FULL/PARTIALLY EXTERNAL PARTICLES


    FIRST OF SAMPLE CHECK SHEET IS
    CHOCKING 5 OIL/COPPER CHIPS /GREASE 3 2 30 NOT REQUIRED NA NA
    IMPLEMENTED
    PROBLEM INSIDE THE TUBE.

    FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    FORMING DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED NA NA
    PARTS IMPARTED
    WEAR & TEAR OF TOOLS 5 TOOL HISTORY CARD IS IMPLEMENTED 2 100 NOT REQUIRED NA NA
    PRESSURE GAUGE DEPLOYED AND
    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED NA NA
    IMPLEMENTED
    IMPROPER IMPROPER SETTING OF MC & M/C SET UP BY CNC TRAINED OPERATOR
    FITMENT PROBLEM 10 YC 3 2 60 NOT REQUIRED NA NA
    DIMENSIONING FIXTURE & VERIFIED BY PROD SUP

    SPECIFIED MANDREL NOT TRAINING IS IMPARTED & FIRST OF


    3 1 30 NOT REQUIRED NA NA
    MANUAL / USED SAMPLE CHECK SHEET IS IMPLEMENTED
    CNC BENDING
    PROPERLY PLACING OF BENDED PART
    APPERANCE NG
    DENTS/ SCRATCHES/ IMPROPER HANDLING/ INTO TROLLY AS PER STANDARD / FIRST
    DENTS/SCRATCHES/ 5 YS 4 4 80 NOT REQUIRED NA NA
    PINCH DEFECTS IN DIE OFF SAMPLE CHECK SHEET IS
    PINCHES
    IMPLEMENTED

    EXTERNAL PARTICLES TCE SOLUTION CHANGE FREQUENCY IS


    T.C.E.
    IMPROPER CLEANING BRAZING PROBLEM 6 OIL/COPPER CHIPS /GREASE 2 DEFINED AS PER NO.OF PIECES WASHED 2 24 NOT REQUIRED NA NA
    CLEANING
    OUTSIDE THE TUBE. & MONITORING SHEET IS MPLEMENTED

    FULL/PARTIALLY EXTERNAL PARTICLES


    TCE SOLUTION CHANGE FREQUENCY IS
    CHOCKING 6 OIL/COPPER CHIPS /GREASE 2 2 24 NOT REQUIRED NA NA
    DEFINED AS PER NO.OF PIECES WASHED.
    PROBLEM INSIDE THE TUBE.

    IMPROPER COPPER CHIPS/EXTERNAL


    CHOCKING BLOWING PRESSURE STD (5-6 KG/CM2) &
    N2 BLOWING /INSUFFICIENT N2 7 PARTICLES REMAIN INSIDE 3 2 42 NOT REQUIRED NA NA
    PROBLEM TIME (5-10 SEC/PCS ) HAS BEEN SET UP
    FLUSHING TUBE

    MOISTURE PRESENT IN THE BLOWING PRESSURE STD (5-6 KG/CM2) &


    FUCTIONING NOT OK 7 3 2 42 NOT REQUIRED NA NA
    TUBE TIME (5-10 SEC/PCS ) HAS BEEN SET UP

    IMPROPER PERIODICALLY TRAINING PROVIDED TO ONLY TRAINED OPERATOR MUST


    FINAL FITMENT FITMENT PROBLEM 8 NEGLEGANCY OF OPERATOR 3 3 72 NA NA
    CHECKING/FITMENT OPERATOR. PERFORM THIS PROCESS
    WEAR & TEAR OF FITMENT PERIODICALLY JIG VERIFICATION IS
    3 2 48 NOT REQUIRED NA NA
    ZIG IMPLEMENTED
    PACKING STANDARD IS DISPLAYED AND
    PACKING/ IMPROPER SHORTAGE/EXCESS PACKING NOT DONE AS PER
    10 YC 3 PERIODICALLY BRAINSTORMING IS 2 60 NOT REQUIRED NA NA
    DISPATCH PACKING/DISPATCH OF MATERIAL STANDARD
    IMPARTED

    PACKING STANDARD IS DISPLAYED AND


    WRONG PACKING DONE DUE
    FITMENT PROBLEM 10 YC 4 PERIODICALLY BRAINSTORMING IS 2 80 NOT REQUIRED NA NA
    TO NEGLEGANCY OF OPT
    IMPARTED

    PERIODICALLY BRAINSTORMING OF
    NEGLENGACY OF PACKING
    MIXING PROBLEM 10 YC 4 OPERATORS & REVERIFICATION BY QC 2 80 NOT REQUIRED NA NA
    OPERATOR
    SUP BEFORE DISPATCH

    NO ACTION RECOMMENDED IF RPN<100


    ACTION RECOMMENDED IF RPN>=150
    IMMEDIATE ACTION IF RPN>150
    RECOMMENDED
    Prepared By: Checked By: Approved BY:

    Page 18 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/25-11-14
    Part name-Suction pipe Part Code-3P386507-1

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN

    RISK PN
    STEP/INPUT MODE EFFECTS

    CLASS
    LENGTH
    FITMENT PROBLEM 10 YC IMPROPER SETTING OF M/C 4 M/C SET UP BY LINE SUPERVISOR 1 40 NOT REQUIRED NA NA
    SHORT/EXCESS
    IMPROPER SETTING OF FIRST OF SAMPLE CHECK SHEET IS
    3 1 30 NOT REQUIRED NA NA
    GUIDE ROLLER IMPLEMENTED.
    CUTTING
    APPERANCE NG
    FIRST OF SAMPLE CHECK SHEET AND
    VISUAL DEFFECT DENTS/SCRATCHES/ 5 YS DEFECTS IN CUTTING M/C DIE 4 2 40 NOT REQUIRED NA NA
    VISUAL INSPECTION IS IMPLEMENTED
    PINCHES
    WEAR & TEAR OF DIE 3 TOOL HISTORY CARD IMPLEMENTED 2 30 NOT REQUIRED NA NA
    EXTERNAL PARTICLES
    IMPROPER CLEANING FIRST OF SAMPLE CHECK SHEET IS
    DEBURRING BRAZING PROBLEM 4 OIL/COPPER CHIPS /GREASE 4 2 32 NOT REQUIRED NA NA
    OF TUBE ENDS IMPLEMENTED
    OUTSIDE THE TUBE.

    FULL/PARTIALLY EXTERNAL PARTICLES


    FIRST OF SAMPLE CHECK SHEET IS
    CHOCKING 5 OIL/COPPER CHIPS /GREASE 3 2 30 NOT REQUIRED NA NA
    IMPLEMENTED
    PROBLEM INSIDE THE TUBE.

    FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    FORMING DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED NA NA
    PARTS IMPARTED
    WEAR & TEAR OF TOOLS 5 TOOL HISTORY CARD IS IMPLEMENTED 2 100 NOT REQUIRED NA NA
    PRESSURE GAUGE DEPLOYED AND
    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED NA NA
    IMPLEMENTED
    IMPROPER IMPROPER SETTING OF MC & M/C SET UP BY CNC TRAINED OPERATOR
    FITMENT PROBLEM 10 YC 3 2 60 NOT REQUIRED NA NA
    DIMENSIONING FIXTURE & VERIFIED BY PROD SUP

    SPECIFIED MANDREL NOT TRAINING IS IMPARTED & FIRST OF


    3 1 30 NOT REQUIRED NA NA
    MANUAL / USED SAMPLE CHECK SHEET IS IMPLEMENTED
    CNC BENDING
    PROPERLY PLACING OF BENDED PART
    APPERANCE NG
    DENTS/ SCRATCHES/ IMPROPER HANDLING/ INTO TROLLY AS PER STANDARD / FIRST
    DENTS/SCRATCHES/ 5 YS 4 4 80 NOT REQUIRED NA NA
    PINCH DEFECTS IN DIE OFF SAMPLE CHECK SHEET IS
    PINCHES
    IMPLEMENTED

    EXTERNAL PARTICLES TCE SOLUTION CHANGE FREQUENCY IS


    T.C.E.
    IMPROPER CLEANING BRAZING PROBLEM 6 OIL/COPPER CHIPS /GREASE 2 DEFINED AS PER NO.OF PIECES WASHED 2 24 NOT REQUIRED NA NA
    CLEANING
    OUTSIDE THE TUBE. & MONITORING SHEET IS MPLEMENTED

    FULL/PARTIALLY EXTERNAL PARTICLES


    TCE SOLUTION CHANGE FREQUENCY IS
    CHOCKING 6 OIL/COPPER CHIPS /GREASE 2 2 24 NOT REQUIRED NA NA
    DEFINED AS PER NO.OF PIECES WASHED.
    PROBLEM INSIDE THE TUBE.

    IMPROPER COPPER CHIPS/EXTERNAL


    CHOCKING BLOWING PRESSURE STD (5-6 KG/CM2) &
    N2 BLOWING /INSUFFICIENT N2 7 PARTICLES REMAIN INSIDE 3 2 42 NOT REQUIRED NA NA
    PROBLEM TIME (5-10 SEC/PCS ) HAS BEEN SET UP
    FLUSHING TUBE

    MOISTURE PRESENT IN THE BLOWING PRESSURE STD (5-6 KG/CM2) &


    FUCTIONING NOT OK 7 3 2 42 NOT REQUIRED NA NA
    TUBE TIME (5-10 SEC/PCS ) HAS BEEN SET UP

    IMPROPER PERIODICALLY TRAINING PROVIDED TO ONLY TRAINED OPERATOR MUST


    FINAL FITMENT FITMENT PROBLEM 8 NEGLEGANCY OF OPERATOR 3 3 72 NA NA
    CHECKING/FITMENT OPERATOR. PERFORM THIS PROCESS
    WEAR & TEAR OF FITMENT PERIODICALLY JIG VERIFICATION IS
    3 2 48 NOT REQUIRED NA NA
    ZIG IMPLEMENTED
    PACKING STANDARD IS DISPLAYED AND
    PACKING/ IMPROPER SHORTAGE/EXCESS PACKING NOT DONE AS PER
    10 YC 3 PERIODICALLY BRAINSTORMING IS 2 60 NOT REQUIRED NA NA
    DISPATCH PACKING/DISPATCH OF MATERIAL STANDARD
    IMPARTED

    PACKING STANDARD IS DISPLAYED AND


    WRONG PACKING DONE DUE
    FITMENT PROBLEM 10 YC 4 PERIODICALLY BRAINSTORMING IS 2 80 NOT REQUIRED NA NA
    TO NEGLEGANCY OF OPT
    IMPARTED

    PERIODICALLY BRAINSTORMING OF
    NEGLENGACY OF PACKING
    MIXING PROBLEM 10 YC 4 OPERATORS & REVERIFICATION BY QC 2 80 NOT REQUIRED NA NA
    OPERATOR
    SUP BEFORE DISPATCH

    NO ACTION RECOMMENDED IF RPN<100


    ACTION RECOMMENDED IF RPN>=150
    IMMEDIATE ACTION IF RPN>150
    RECOMMENDED
    Prepared By: Checked By: Approved BY:

    Page 19 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/25-11-14
    Part name-Suction pipe Part Code-3P386443-1

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN

    RISK PN
    STEP/INPUT MODE EFFECTS

    CLASS
    LENGTH
    FITMENT PROBLEM 10 YC IMPROPER SETTING OF M/C 4 M/C SET UP BY LINE SUPERVISOR 1 40 NOT REQUIRED NA NA
    SHORT/EXCESS
    IMPROPER SETTING OF FIRST OF SAMPLE CHECK SHEET IS
    3 1 30 NOT REQUIRED NA NA
    GUIDE ROLLER IMPLEMENTED.
    CUTTING
    APPERANCE NG
    FIRST OF SAMPLE CHECK SHEET AND
    VISUAL DEFFECT DENTS/SCRATCHES/ 5 YS DEFECTS IN CUTTING M/C DIE 4 2 40 NOT REQUIRED NA NA
    VISUAL INSPECTION IS IMPLEMENTED
    PINCHES
    WEAR & TEAR OF DIE 3 TOOL HISTORY CARD IMPLEMENTED 2 30 NOT REQUIRED NA NA
    EXTERNAL PARTICLES
    IMPROPER CLEANING FIRST OF SAMPLE CHECK SHEET IS
    DEBURRING BRAZING PROBLEM 4 OIL/COPPER CHIPS /GREASE 4 2 32 NOT REQUIRED NA NA
    OF TUBE ENDS IMPLEMENTED
    OUTSIDE THE TUBE.

    FULL/PARTIALLY EXTERNAL PARTICLES


    FIRST OF SAMPLE CHECK SHEET IS
    CHOCKING 5 OIL/COPPER CHIPS /GREASE 3 2 30 NOT REQUIRED NA NA
    IMPLEMENTED
    PROBLEM INSIDE THE TUBE.
    IMPROPER IMPROPER SETTING OF MC & M/C SET UP BY CNC TRAINED OPERATOR
    FITMENT PROBLEM 10 YC 3 2 60 NOT REQUIRED NA NA
    DIMENSIONING FIXTURE & VERIFIED BY PROD SUP

    SPECIFIED MANDREL NOT TRAINING IS IMPARTED & FIRST OF


    3 1 30 NOT REQUIRED NA NA
    MANUAL / USED SAMPLE CHECK SHEET IS IMPLEMENTED
    CNC BENDING
    PROPERLY PLACING OF BENDED PART
    APPERANCE NG
    DENTS/ SCRATCHES/ IMPROPER HANDLING/ INTO TROLLY AS PER STANDARD / FIRST
    DENTS/SCRATCHES/ 5 YS 4 4 80 NOT REQUIRED NA NA
    PINCH DEFECTS IN DIE OFF SAMPLE CHECK SHEET IS
    PINCHES
    IMPLEMENTED

    EXTERNAL PARTICLES TCE SOLUTION CHANGE FREQUENCY IS


    T.C.E.
    IMPROPER CLEANING BRAZING PROBLEM 6 OIL/COPPER CHIPS /GREASE 2 DEFINED AS PER NO.OF PIECES WASHED 2 24 NOT REQUIRED NA NA
    CLEANING
    OUTSIDE THE TUBE. & MONITORING SHEET IS MPLEMENTED

    FULL/PARTIALLY EXTERNAL PARTICLES


    TCE SOLUTION CHANGE FREQUENCY IS
    CHOCKING 6 OIL/COPPER CHIPS /GREASE 2 2 24 NOT REQUIRED NA NA
    DEFINED AS PER NO.OF PIECES WASHED.
    PROBLEM INSIDE THE TUBE.

    IMPROPER COPPER CHIPS/EXTERNAL


    CHOCKING BLOWING PRESSURE STD (5-6 KG/CM2) &
    N2 BLOWING /INSUFFICIENT N2 7 PARTICLES REMAIN INSIDE 3 2 42 NOT REQUIRED NA NA
    PROBLEM TIME (5-10 SEC/PCS ) HAS BEEN SET UP
    FLUSHING TUBE

    MOISTURE PRESENT IN THE BLOWING PRESSURE STD (5-6 KG/CM2) &


    FUCTIONING NOT OK 7 3 2 42 NOT REQUIRED NA NA
    TUBE TIME (5-10 SEC/PCS ) HAS BEEN SET UP

    IMPROPER PERIODICALLY TRAINING PROVIDED TO ONLY TRAINED OPERATOR MUST


    FINAL FITMENT FITMENT PROBLEM 8 NEGLEGANCY OF OPERATOR 3 3 72 NA NA
    CHECKING/FITMENT OPERATOR. PERFORM THIS PROCESS
    WEAR & TEAR OF FITMENT PERIODICALLY JIG VERIFICATION IS
    3 2 48 NOT REQUIRED NA NA
    ZIG IMPLEMENTED
    PACKING STANDARD IS DISPLAYED AND
    PACKING/ IMPROPER SHORTAGE/EXCESS PACKING NOT DONE AS PER
    10 YC 3 PERIODICALLY BRAINSTORMING IS 2 60 NOT REQUIRED NA NA
    DISPATCH PACKING/DISPATCH OF MATERIAL STANDARD
    IMPARTED

    PACKING STANDARD IS DISPLAYED AND


    WRONG PACKING DONE DUE
    FITMENT PROBLEM 10 YC 4 PERIODICALLY BRAINSTORMING IS 2 80 NOT REQUIRED NA NA
    TO NEGLEGANCY OF OPT
    IMPARTED

    PERIODICALLY BRAINSTORMING OF
    NEGLENGACY OF PACKING
    MIXING PROBLEM 10 YC 4 OPERATORS & REVERIFICATION BY QC 2 80 NOT REQUIRED NA NA
    OPERATOR
    SUP BEFORE DISPATCH

    NO ACTION RECOMMENDED IF RPN<100


    ACTION RECOMMENDED IF RPN>=150
    IMMEDIATE ACTION IF RPN>150
    RECOMMENDED
    Prepared By: Checked By: Approved BY:

    Page 20 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/25-11-14
    Part name-Suction pipe Part Code-3P381627-1A

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN

    RISK PN
    STEP/INPUT MODE EFFECTS

    CLASS
    LENGTH
    FITMENT PROBLEM 10 YC IMPROPER SETTING OF M/C 4 M/C SET UP BY LINE SUPERVISOR 1 40 NOT REQUIRED NA NA
    SHORT/EXCESS
    IMPROPER SETTING OF FIRST OF SAMPLE CHECK SHEET IS
    3 1 30 NOT REQUIRED NA NA
    GUIDE ROLLER IMPLEMENTED.
    CUTTING
    APPERANCE NG
    FIRST OF SAMPLE CHECK SHEET AND
    VISUAL DEFFECT DENTS/SCRATCHES/ 5 YS DEFECTS IN CUTTING M/C DIE 4 2 40 NOT REQUIRED NA NA
    VISUAL INSPECTION IS IMPLEMENTED
    PINCHES
    WEAR & TEAR OF DIE 3 TOOL HISTORY CARD IMPLEMENTED 2 30 NOT REQUIRED NA NA
    EXTERNAL PARTICLES
    IMPROPER CLEANING FIRST OF SAMPLE CHECK SHEET IS
    DEBURRING BRAZING PROBLEM 4 OIL/COPPER CHIPS /GREASE 4 2 32 NOT REQUIRED NA NA
    OF TUBE ENDS IMPLEMENTED
    OUTSIDE THE TUBE.

    FULL/PARTIALLY EXTERNAL PARTICLES


    FIRST OF SAMPLE CHECK SHEET IS
    CHOCKING 5 OIL/COPPER CHIPS /GREASE 3 2 30 NOT REQUIRED NA NA
    IMPLEMENTED
    PROBLEM INSIDE THE TUBE.

    FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    FORMING DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED NA NA
    PARTS IMPARTED
    WEAR & TEAR OF TOOLS 5 TOOL HISTORY CARD IS IMPLEMENTED 2 100 NOT REQUIRED NA NA
    PRESSURE GAUGE DEPLOYED AND
    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED NA NA
    IMPLEMENTED
    IMPROPER IMPROPER SETTING OF MC & M/C SET UP BY CNC TRAINED OPERATOR
    FITMENT PROBLEM 10 YC 3 2 60 NOT REQUIRED NA NA
    DIMENSIONING FIXTURE & VERIFIED BY PROD SUP

    SPECIFIED MANDREL NOT TRAINING IS IMPARTED & FIRST OF


    3 1 30 NOT REQUIRED NA NA
    MANUAL / USED SAMPLE CHECK SHEET IS IMPLEMENTED
    CNC BENDING
    PROPERLY PLACING OF BENDED PART
    APPERANCE NG
    DENTS/ SCRATCHES/ IMPROPER HANDLING/ INTO TROLLY AS PER STANDARD / FIRST
    DENTS/SCRATCHES/ 5 YS 4 4 80 NOT REQUIRED NA NA
    PINCH DEFECTS IN DIE OFF SAMPLE CHECK SHEET IS
    PINCHES
    IMPLEMENTED

    EXTERNAL PARTICLES TCE SOLUTION CHANGE FREQUENCY IS


    T.C.E.
    IMPROPER CLEANING BRAZING PROBLEM 6 OIL/COPPER CHIPS /GREASE 2 DEFINED AS PER NO.OF PIECES WASHED 2 24 NOT REQUIRED NA NA
    CLEANING
    OUTSIDE THE TUBE. & MONITORING SHEET IS MPLEMENTED

    FULL/PARTIALLY EXTERNAL PARTICLES


    TCE SOLUTION CHANGE FREQUENCY IS
    CHOCKING 6 OIL/COPPER CHIPS /GREASE 2 2 24 NOT REQUIRED NA NA
    DEFINED AS PER NO.OF PIECES WASHED.
    PROBLEM INSIDE THE TUBE.

    IMPROPER COPPER CHIPS/EXTERNAL


    CHOCKING BLOWING PRESSURE STD (5-6 KG/CM2) &
    N2 BLOWING /INSUFFICIENT N2 7 PARTICLES REMAIN INSIDE 3 2 42 NOT REQUIRED NA NA
    PROBLEM TIME (5-10 SEC/PCS ) HAS BEEN SET UP
    FLUSHING TUBE

    MOISTURE PRESENT IN THE BLOWING PRESSURE STD (5-6 KG/CM2) &


    FUCTIONING NOT OK 7 3 2 42 NOT REQUIRED NA NA
    TUBE TIME (5-10 SEC/PCS ) HAS BEEN SET UP

    IMPROPER PERIODICALLY TRAINING PROVIDED TO ONLY TRAINED OPERATOR MUST


    FINAL FITMENT FITMENT PROBLEM 8 NEGLEGANCY OF OPERATOR 3 3 72 NA NA
    CHECKING/FITMENT OPERATOR. PERFORM THIS PROCESS
    WEAR & TEAR OF FITMENT PERIODICALLY JIG VERIFICATION IS
    3 2 48 NOT REQUIRED NA NA
    ZIG IMPLEMENTED
    PACKING STANDARD IS DISPLAYED AND
    PACKING/ IMPROPER SHORTAGE/EXCESS PACKING NOT DONE AS PER
    10 YC 3 PERIODICALLY BRAINSTORMING IS 2 60 NOT REQUIRED NA NA
    DISPATCH PACKING/DISPATCH OF MATERIAL STANDARD
    IMPARTED

    PACKING STANDARD IS DISPLAYED AND


    WRONG PACKING DONE DUE
    FITMENT PROBLEM 10 YC 4 PERIODICALLY BRAINSTORMING IS 2 80 NOT REQUIRED NA NA
    TO NEGLEGANCY OF OPT
    IMPARTED

    PERIODICALLY BRAINSTORMING OF
    NEGLENGACY OF PACKING
    MIXING PROBLEM 10 YC 4 OPERATORS & REVERIFICATION BY QC 2 80 NOT REQUIRED NA NA
    OPERATOR
    SUP BEFORE DISPATCH

    NO ACTION RECOMMENDED IF RPN<100


    ACTION RECOMMENDED IF RPN>=150
    IMMEDIATE ACTION IF RPN>150
    RECOMMENDED
    Prepared By: Checked By: Approved BY:

    Page 21 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/25-11-14
    Part name-Suction pipe Part Code-3P387167-1

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN

    RISK PN
    STEP/INPUT MODE EFFECTS

    CLASS
    LENGTH
    FITMENT PROBLEM 10 YC IMPROPER SETTING OF M/C 4 M/C SET UP BY LINE SUPERVISOR 1 40 NOT REQUIRED NA NA
    SHORT/EXCESS
    IMPROPER SETTING OF FIRST OF SAMPLE CHECK SHEET IS
    3 1 30 NOT REQUIRED NA NA
    GUIDE ROLLER IMPLEMENTED.
    CUTTING
    APPERANCE NG
    FIRST OF SAMPLE CHECK SHEET AND
    VISUAL DEFFECT DENTS/SCRATCHES/ 5 YS DEFECTS IN CUTTING M/C DIE 4 2 40 NOT REQUIRED NA NA
    VISUAL INSPECTION IS IMPLEMENTED
    PINCHES
    WEAR & TEAR OF DIE 3 TOOL HISTORY CARD IMPLEMENTED 2 30 NOT REQUIRED NA NA
    EXTERNAL PARTICLES
    IMPROPER CLEANING FIRST OF SAMPLE CHECK SHEET IS
    DEBURRING BRAZING PROBLEM 4 OIL/COPPER CHIPS /GREASE 4 2 32 NOT REQUIRED NA NA
    OF TUBE ENDS IMPLEMENTED
    OUTSIDE THE TUBE.

    FULL/PARTIALLY EXTERNAL PARTICLES


    FIRST OF SAMPLE CHECK SHEET IS
    CHOCKING 5 OIL/COPPER CHIPS /GREASE 3 2 30 NOT REQUIRED NA NA
    IMPLEMENTED
    PROBLEM INSIDE THE TUBE.
    IMPROPER IMPROPER SETTING OF MC & M/C SET UP BY CNC TRAINED OPERATOR
    FITMENT PROBLEM 10 YC 3 2 60 NOT REQUIRED NA NA
    DIMENSIONING FIXTURE & VERIFIED BY PROD SUP

    SPECIFIED MANDREL NOT TRAINING IS IMPARTED & FIRST OF


    3 1 30 NOT REQUIRED NA NA
    MANUAL / USED SAMPLE CHECK SHEET IS IMPLEMENTED
    CNC BENDING
    PROPERLY PLACING OF BENDED PART
    APPERANCE NG
    DENTS/ SCRATCHES/ IMPROPER HANDLING/ INTO TROLLY AS PER STANDARD / FIRST
    DENTS/SCRATCHES/ 5 YS 4 4 80 NOT REQUIRED NA NA
    PINCH DEFECTS IN DIE OFF SAMPLE CHECK SHEET IS
    PINCHES
    IMPLEMENTED

    EXTERNAL PARTICLES TCE SOLUTION CHANGE FREQUENCY IS


    T.C.E.
    IMPROPER CLEANING BRAZING PROBLEM 6 OIL/COPPER CHIPS /GREASE 2 DEFINED AS PER NO.OF PIECES WASHED 2 24 NOT REQUIRED NA NA
    CLEANING
    OUTSIDE THE TUBE. & MONITORING SHEET IS MPLEMENTED

    FULL/PARTIALLY EXTERNAL PARTICLES


    TCE SOLUTION CHANGE FREQUENCY IS
    CHOCKING 6 OIL/COPPER CHIPS /GREASE 2 2 24 NOT REQUIRED NA NA
    DEFINED AS PER NO.OF PIECES WASHED.
    PROBLEM INSIDE THE TUBE.

    IMPROPER COPPER CHIPS/EXTERNAL


    CHOCKING BLOWING PRESSURE STD (5-6 KG/CM2) &
    N2 BLOWING /INSUFFICIENT N2 7 PARTICLES REMAIN INSIDE 3 2 42 NOT REQUIRED NA NA
    PROBLEM TIME (5-10 SEC/PCS ) HAS BEEN SET UP
    FLUSHING TUBE

    MOISTURE PRESENT IN THE BLOWING PRESSURE STD (5-6 KG/CM2) &


    FUCTIONING NOT OK 7 3 2 42 NOT REQUIRED NA NA
    TUBE TIME (5-10 SEC/PCS ) HAS BEEN SET UP

    IMPROPER PERIODICALLY TRAINING PROVIDED TO ONLY TRAINED OPERATOR MUST


    FINAL FITMENT FITMENT PROBLEM 8 NEGLEGANCY OF OPERATOR 3 3 72 NA NA
    CHECKING/FITMENT OPERATOR. PERFORM THIS PROCESS
    WEAR & TEAR OF FITMENT PERIODICALLY JIG VERIFICATION IS
    3 2 48 NOT REQUIRED NA NA
    ZIG IMPLEMENTED
    PACKING STANDARD IS DISPLAYED AND
    PACKING/ IMPROPER SHORTAGE/EXCESS PACKING NOT DONE AS PER
    10 YC 3 PERIODICALLY BRAINSTORMING IS 2 60 NOT REQUIRED NA NA
    DISPATCH PACKING/DISPATCH OF MATERIAL STANDARD
    IMPARTED

    PACKING STANDARD IS DISPLAYED AND


    WRONG PACKING DONE DUE
    FITMENT PROBLEM 10 YC 4 PERIODICALLY BRAINSTORMING IS 2 80 NOT REQUIRED NA NA
    TO NEGLEGANCY OF OPT
    IMPARTED

    PERIODICALLY BRAINSTORMING OF
    NEGLENGACY OF PACKING
    MIXING PROBLEM 10 YC 4 OPERATORS & REVERIFICATION BY QC 2 80 NOT REQUIRED NA NA
    OPERATOR
    SUP BEFORE DISPATCH

    NO ACTION RECOMMENDED IF RPN<100


    ACTION RECOMMENDED IF RPN>=150
    IMMEDIATE ACTION IF RPN>150
    RECOMMENDED
    Prepared By: Checked By: Approved BY:

    Page 22 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/25-11-14
    Part name-Suction pipe Part Code-3P387327-1

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN

    RISK PN
    STEP/INPUT MODE EFFECTS

    CLASS
    LENGTH
    FITMENT PROBLEM 10 YC IMPROPER SETTING OF M/C 4 M/C SET UP BY LINE SUPERVISOR 1 40 NOT REQUIRED NA NA
    SHORT/EXCESS
    IMPROPER SETTING OF FIRST OF SAMPLE CHECK SHEET IS
    3 1 30 NOT REQUIRED NA NA
    GUIDE ROLLER IMPLEMENTED.
    CUTTING
    APPERANCE NG
    FIRST OF SAMPLE CHECK SHEET AND
    VISUAL DEFFECT DENTS/SCRATCHES/ 5 YS DEFECTS IN CUTTING M/C DIE 4 2 40 NOT REQUIRED NA NA
    VISUAL INSPECTION IS IMPLEMENTED
    PINCHES
    WEAR & TEAR OF DIE 3 TOOL HISTORY CARD IMPLEMENTED 2 30 NOT REQUIRED NA NA
    EXTERNAL PARTICLES
    IMPROPER CLEANING FIRST OF SAMPLE CHECK SHEET IS
    DEBURRING BRAZING PROBLEM 4 OIL/COPPER CHIPS /GREASE 4 2 32 NOT REQUIRED NA NA
    OF TUBE ENDS IMPLEMENTED
    OUTSIDE THE TUBE.

    FULL/PARTIALLY EXTERNAL PARTICLES


    FIRST OF SAMPLE CHECK SHEET IS
    CHOCKING 5 OIL/COPPER CHIPS /GREASE 3 2 30 NOT REQUIRED NA NA
    IMPLEMENTED
    PROBLEM INSIDE THE TUBE.

    FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    FORMING DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED NA NA
    PARTS IMPARTED
    WEAR & TEAR OF TOOLS 5 TOOL HISTORY CARD IS IMPLEMENTED 2 100 NOT REQUIRED NA NA
    PRESSURE GAUGE DEPLOYED AND
    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED NA NA
    IMPLEMENTED
    IMPROPER IMPROPER SETTING OF MC & M/C SET UP BY CNC TRAINED OPERATOR
    FITMENT PROBLEM 10 YC 3 2 60 NOT REQUIRED NA NA
    DIMENSIONING FIXTURE & VERIFIED BY PROD SUP

    SPECIFIED MANDREL NOT TRAINING IS IMPARTED & FIRST OF


    3 1 30 NOT REQUIRED NA NA
    MANUAL / USED SAMPLE CHECK SHEET IS IMPLEMENTED
    CNC BENDING
    PROPERLY PLACING OF BENDED PART
    APPERANCE NG
    DENTS/ SCRATCHES/ IMPROPER HANDLING/ INTO TROLLY AS PER STANDARD / FIRST
    DENTS/SCRATCHES/ 5 YS 4 4 80 NOT REQUIRED NA NA
    PINCH DEFECTS IN DIE OFF SAMPLE CHECK SHEET IS
    PINCHES
    IMPLEMENTED

    EXTERNAL PARTICLES TCE SOLUTION CHANGE FREQUENCY IS


    T.C.E.
    IMPROPER CLEANING BRAZING PROBLEM 6 OIL/COPPER CHIPS /GREASE 2 DEFINED AS PER NO.OF PIECES WASHED 2 24 NOT REQUIRED NA NA
    CLEANING
    OUTSIDE THE TUBE. & MONITORING SHEET IS MPLEMENTED

    FULL/PARTIALLY EXTERNAL PARTICLES


    TCE SOLUTION CHANGE FREQUENCY IS
    CHOCKING 6 OIL/COPPER CHIPS /GREASE 2 2 24 NOT REQUIRED NA NA
    DEFINED AS PER NO.OF PIECES WASHED.
    PROBLEM INSIDE THE TUBE.

    IMPROPER COPPER CHIPS/EXTERNAL


    CHOCKING BLOWING PRESSURE STD (5-6 KG/CM2) &
    N2 BLOWING /INSUFFICIENT N2 7 PARTICLES REMAIN INSIDE 3 2 42 NOT REQUIRED NA NA
    PROBLEM TIME (5-10 SEC/PCS ) HAS BEEN SET UP
    FLUSHING TUBE

    MOISTURE PRESENT IN THE BLOWING PRESSURE STD (5-6 KG/CM2) &


    FUCTIONING NOT OK 7 3 2 42 NOT REQUIRED NA NA
    TUBE TIME (5-10 SEC/PCS ) HAS BEEN SET UP

    IMPROPER PERIODICALLY TRAINING PROVIDED TO ONLY TRAINED OPERATOR MUST


    FINAL FITMENT FITMENT PROBLEM 8 NEGLEGANCY OF OPERATOR 3 3 72 NA NA
    CHECKING/FITMENT OPERATOR. PERFORM THIS PROCESS
    WEAR & TEAR OF FITMENT PERIODICALLY JIG VERIFICATION IS
    3 2 48 NOT REQUIRED NA NA
    ZIG IMPLEMENTED
    PACKING STANDARD IS DISPLAYED AND
    PACKING/ IMPROPER SHORTAGE/EXCESS PACKING NOT DONE AS PER
    10 YC 3 PERIODICALLY BRAINSTORMING IS 2 60 NOT REQUIRED NA NA
    DISPATCH PACKING/DISPATCH OF MATERIAL STANDARD
    IMPARTED

    PACKING STANDARD IS DISPLAYED AND


    WRONG PACKING DONE DUE
    FITMENT PROBLEM 10 YC 4 PERIODICALLY BRAINSTORMING IS 2 80 NOT REQUIRED NA NA
    TO NEGLEGANCY OF OPT
    IMPARTED

    PERIODICALLY BRAINSTORMING OF
    NEGLENGACY OF PACKING
    MIXING PROBLEM 10 YC 4 OPERATORS & REVERIFICATION BY QC 2 80 NOT REQUIRED NA NA
    OPERATOR
    SUP BEFORE DISPATCH

    NO ACTION RECOMMENDED IF RPN<100


    ACTION RECOMMENDED IF RPN>=150
    IMMEDIATE ACTION IF RPN>150
    RECOMMENDED
    Prepared By: Checked By: Approved BY:

    Page 23 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/25-11-14
    Part name-Discharge pipe Part Code-3P386494-1

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN

    RISK PN
    STEP/INPUT MODE EFFECTS

    CLASS
    LENGTH
    FITMENT PROBLEM 10 YC IMPROPER SETTING OF M/C 4 M/C SET UP BY LINE SUPERVISOR 1 40 NOT REQUIRED NA NA
    SHORT/EXCESS
    IMPROPER SETTING OF FIRST OF SAMPLE CHECK SHEET IS
    3 1 30 NOT REQUIRED NA NA
    GUIDE ROLLER IMPLEMENTED.
    CUTTING
    APPERANCE NG
    FIRST OF SAMPLE CHECK SHEET AND
    VISUAL DEFFECT DENTS/SCRATCHES/ 5 YS DEFECTS IN CUTTING M/C DIE 4 2 40 NOT REQUIRED NA NA
    VISUAL INSPECTION IS IMPLEMENTED
    PINCHES
    WEAR & TEAR OF DIE 3 TOOL HISTORY CARD IMPLEMENTED 2 30 NOT REQUIRED NA NA
    EXTERNAL PARTICLES
    IMPROPER CLEANING FIRST OF SAMPLE CHECK SHEET IS
    DEBURRING BRAZING PROBLEM 4 OIL/COPPER CHIPS /GREASE 4 2 32 NOT REQUIRED NA NA
    OF TUBE ENDS IMPLEMENTED
    OUTSIDE THE TUBE.

    FULL/PARTIALLY EXTERNAL PARTICLES


    FIRST OF SAMPLE CHECK SHEET IS
    CHOCKING 5 OIL/COPPER CHIPS /GREASE 3 2 30 NOT REQUIRED NA NA
    IMPLEMENTED
    PROBLEM INSIDE THE TUBE.

    FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    FORMING DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED NA NA
    PARTS IMPARTED
    WEAR & TEAR OF TOOLS 5 TOOL HISTORY CARD IS IMPLEMENTED 2 100 NOT REQUIRED NA NA
    PRESSURE GAUGE DEPLOYED AND
    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED NA NA
    IMPLEMENTED
    IMPROPER IMPROPER SETTING OF MC & M/C SET UP BY CNC TRAINED OPERATOR
    FITMENT PROBLEM 10 YC 3 2 60 NOT REQUIRED NA NA
    DIMENSIONING FIXTURE & VERIFIED BY PROD SUP

    SPECIFIED MANDREL NOT TRAINING IS IMPARTED & FIRST OF


    3 1 30 NOT REQUIRED NA NA
    MANUAL / USED SAMPLE CHECK SHEET IS IMPLEMENTED
    CNC BENDING
    PROPERLY PLACING OF BENDED PART
    APPERANCE NG
    DENTS/ SCRATCHES/ IMPROPER HANDLING/ INTO TROLLY AS PER STANDARD / FIRST
    DENTS/SCRATCHES/ 5 YS 4 4 80 NOT REQUIRED NA NA
    PINCH DEFECTS IN DIE OFF SAMPLE CHECK SHEET IS
    PINCHES
    IMPLEMENTED

    EXTERNAL PARTICLES TCE SOLUTION CHANGE FREQUENCY IS


    T.C.E.
    IMPROPER CLEANING BRAZING PROBLEM 6 OIL/COPPER CHIPS /GREASE 2 DEFINED AS PER NO.OF PIECES WASHED 2 24 NOT REQUIRED NA NA
    CLEANING
    OUTSIDE THE TUBE. & MONITORING SHEET IS MPLEMENTED

    FULL/PARTIALLY EXTERNAL PARTICLES


    TCE SOLUTION CHANGE FREQUENCY IS
    CHOCKING 6 OIL/COPPER CHIPS /GREASE 2 2 24 NOT REQUIRED NA NA
    DEFINED AS PER NO.OF PIECES WASHED.
    PROBLEM INSIDE THE TUBE.

    IMPROPER COPPER CHIPS/EXTERNAL


    CHOCKING BLOWING PRESSURE STD (5-6 KG/CM2) &
    N2 BLOWING /INSUFFICIENT N2 7 PARTICLES REMAIN INSIDE 3 2 42 NOT REQUIRED NA NA
    PROBLEM TIME (5-10 SEC/PCS ) HAS BEEN SET UP
    FLUSHING TUBE

    MOISTURE PRESENT IN THE BLOWING PRESSURE STD (5-6 KG/CM2) &


    FUCTIONING NOT OK 7 3 2 42 NOT REQUIRED NA NA
    TUBE TIME (5-10 SEC/PCS ) HAS BEEN SET UP

    IMPROPER PERIODICALLY TRAINING PROVIDED TO ONLY TRAINED OPERATOR MUST


    FINAL FITMENT FITMENT PROBLEM 8 NEGLEGANCY OF OPERATOR 3 3 72 NA NA
    CHECKING/FITMENT OPERATOR. PERFORM THIS PROCESS
    WEAR & TEAR OF FITMENT PERIODICALLY JIG VERIFICATION IS
    3 2 48 NOT REQUIRED NA NA
    ZIG IMPLEMENTED
    PACKING STANDARD IS DISPLAYED AND
    PACKING/ IMPROPER SHORTAGE/EXCESS PACKING NOT DONE AS PER
    10 YC 3 PERIODICALLY BRAINSTORMING IS 2 60 NOT REQUIRED NA NA
    DISPATCH PACKING/DISPATCH OF MATERIAL STANDARD
    IMPARTED

    PACKING STANDARD IS DISPLAYED AND


    WRONG PACKING DONE DUE
    FITMENT PROBLEM 10 YC 4 PERIODICALLY BRAINSTORMING IS 2 80 NOT REQUIRED NA NA
    TO NEGLEGANCY OF OPT
    IMPARTED

    PERIODICALLY BRAINSTORMING OF
    NEGLENGACY OF PACKING
    MIXING PROBLEM 10 YC 4 OPERATORS & REVERIFICATION BY QC 2 80 NOT REQUIRED NA NA
    OPERATOR
    SUP BEFORE DISPATCH

    NO ACTION RECOMMENDED IF RPN<100


    ACTION RECOMMENDED IF RPN>=150
    IMMEDIATE ACTION IF RPN>150
    RECOMMENDED
    Prepared By: Checked By: Approved BY:

    Page 24 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/25-11-14
    Part name-Discharge pipe Part Code-3P386120-1

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN

    RISK PN
    STEP/INPUT MODE EFFECTS

    CLASS
    LENGTH
    FITMENT PROBLEM 10 YC IMPROPER SETTING OF M/C 4 M/C SET UP BY LINE SUPERVISOR 1 40 NOT REQUIRED NA NA
    SHORT/EXCESS
    IMPROPER SETTING OF FIRST OF SAMPLE CHECK SHEET IS
    3 1 30 NOT REQUIRED NA NA
    GUIDE ROLLER IMPLEMENTED.
    CUTTING
    APPERANCE NG
    FIRST OF SAMPLE CHECK SHEET AND
    VISUAL DEFFECT DENTS/SCRATCHES/ 5 YS DEFECTS IN CUTTING M/C DIE 4 2 40 NOT REQUIRED NA NA
    VISUAL INSPECTION IS IMPLEMENTED
    PINCHES
    WEAR & TEAR OF DIE 3 TOOL HISTORY CARD IMPLEMENTED 2 30 NOT REQUIRED NA NA
    EXTERNAL PARTICLES
    IMPROPER CLEANING FIRST OF SAMPLE CHECK SHEET IS
    DEBURRING BRAZING PROBLEM 4 OIL/COPPER CHIPS /GREASE 4 2 32 NOT REQUIRED NA NA
    OF TUBE ENDS IMPLEMENTED
    OUTSIDE THE TUBE.

    FULL/PARTIALLY EXTERNAL PARTICLES


    FIRST OF SAMPLE CHECK SHEET IS
    CHOCKING 5 OIL/COPPER CHIPS /GREASE 3 2 30 NOT REQUIRED NA NA
    IMPLEMENTED
    PROBLEM INSIDE THE TUBE.

    FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    FORMING DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED NA NA
    PARTS IMPARTED
    WEAR & TEAR OF TOOLS 5 TOOL HISTORY CARD IS IMPLEMENTED 2 100 NOT REQUIRED NA NA
    PRESSURE GAUGE DEPLOYED AND
    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED NA NA
    IMPLEMENTED
    IMPROPER IMPROPER SETTING OF MC & M/C SET UP BY CNC TRAINED OPERATOR
    FITMENT PROBLEM 10 YC 3 2 60 NOT REQUIRED NA NA
    DIMENSIONING FIXTURE & VERIFIED BY PROD SUP

    SPECIFIED MANDREL NOT TRAINING IS IMPARTED & FIRST OF


    3 1 30 NOT REQUIRED NA NA
    MANUAL / USED SAMPLE CHECK SHEET IS IMPLEMENTED
    CNC BENDING
    PROPERLY PLACING OF BENDED PART
    APPERANCE NG
    DENTS/ SCRATCHES/ IMPROPER HANDLING/ INTO TROLLY AS PER STANDARD / FIRST
    DENTS/SCRATCHES/ 5 YS 4 4 80 NOT REQUIRED NA NA
    PINCH DEFECTS IN DIE OFF SAMPLE CHECK SHEET IS
    PINCHES
    IMPLEMENTED

    EXTERNAL PARTICLES TCE SOLUTION CHANGE FREQUENCY IS


    T.C.E.
    IMPROPER CLEANING BRAZING PROBLEM 6 OIL/COPPER CHIPS /GREASE 2 DEFINED AS PER NO.OF PIECES WASHED 2 24 NOT REQUIRED NA NA
    CLEANING
    OUTSIDE THE TUBE. & MONITORING SHEET IS MPLEMENTED

    FULL/PARTIALLY EXTERNAL PARTICLES


    TCE SOLUTION CHANGE FREQUENCY IS
    CHOCKING 6 OIL/COPPER CHIPS /GREASE 2 2 24 NOT REQUIRED NA NA
    DEFINED AS PER NO.OF PIECES WASHED.
    PROBLEM INSIDE THE TUBE.

    IMPROPER COPPER CHIPS/EXTERNAL


    CHOCKING BLOWING PRESSURE STD (5-6 KG/CM2) &
    N2 BLOWING /INSUFFICIENT N2 7 PARTICLES REMAIN INSIDE 3 2 42 NOT REQUIRED NA NA
    PROBLEM TIME (5-10 SEC/PCS ) HAS BEEN SET UP
    FLUSHING TUBE

    MOISTURE PRESENT IN THE BLOWING PRESSURE STD (5-6 KG/CM2) &


    FUCTIONING NOT OK 7 3 2 42 NOT REQUIRED NA NA
    TUBE TIME (5-10 SEC/PCS ) HAS BEEN SET UP

    IMPROPER PERIODICALLY TRAINING PROVIDED TO ONLY TRAINED OPERATOR MUST


    FINAL FITMENT FITMENT PROBLEM 8 NEGLEGANCY OF OPERATOR 3 3 72 NA NA
    CHECKING/FITMENT OPERATOR. PERFORM THIS PROCESS
    WEAR & TEAR OF FITMENT PERIODICALLY JIG VERIFICATION IS
    3 2 48 NOT REQUIRED NA NA
    ZIG IMPLEMENTED
    PACKING STANDARD IS DISPLAYED AND
    PACKING/ IMPROPER SHORTAGE/EXCESS PACKING NOT DONE AS PER
    10 YC 3 PERIODICALLY BRAINSTORMING IS 2 60 NOT REQUIRED NA NA
    DISPATCH PACKING/DISPATCH OF MATERIAL STANDARD
    IMPARTED

    PACKING STANDARD IS DISPLAYED AND


    WRONG PACKING DONE DUE
    FITMENT PROBLEM 10 YC 4 PERIODICALLY BRAINSTORMING IS 2 80 NOT REQUIRED NA NA
    TO NEGLEGANCY OF OPT
    IMPARTED

    PERIODICALLY BRAINSTORMING OF
    NEGLENGACY OF PACKING
    MIXING PROBLEM 10 YC 4 OPERATORS & REVERIFICATION BY QC 2 80 NOT REQUIRED NA NA
    OPERATOR
    SUP BEFORE DISPATCH

    NO ACTION RECOMMENDED IF RPN<100


    ACTION RECOMMENDED IF RPN>=150
    IMMEDIATE ACTION IF RPN>150
    RECOMMENDED
    Prepared By: Checked By: Approved BY:

    Page 25 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/25-11-14
    Part name-Discharge pipe Part Code-3P386542-1

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN

    RISK PN
    STEP/INPUT MODE EFFECTS

    CLASS
    LENGTH
    FITMENT PROBLEM 10 YC IMPROPER SETTING OF M/C 4 M/C SET UP BY LINE SUPERVISOR 1 40 NOT REQUIRED NA NA
    SHORT/EXCESS
    IMPROPER SETTING OF FIRST OF SAMPLE CHECK SHEET IS
    3 1 30 NOT REQUIRED NA NA
    GUIDE ROLLER IMPLEMENTED.
    CUTTING
    APPERANCE NG
    FIRST OF SAMPLE CHECK SHEET AND
    VISUAL DEFFECT DENTS/SCRATCHES/ 5 YS DEFECTS IN CUTTING M/C DIE 4 2 40 NOT REQUIRED NA NA
    VISUAL INSPECTION IS IMPLEMENTED
    PINCHES
    WEAR & TEAR OF DIE 3 TOOL HISTORY CARD IMPLEMENTED 2 30 NOT REQUIRED NA NA
    EXTERNAL PARTICLES
    IMPROPER CLEANING FIRST OF SAMPLE CHECK SHEET IS
    DEBURRING BRAZING PROBLEM 4 OIL/COPPER CHIPS /GREASE 4 2 32 NOT REQUIRED NA NA
    OF TUBE ENDS IMPLEMENTED
    OUTSIDE THE TUBE.

    FULL/PARTIALLY EXTERNAL PARTICLES


    FIRST OF SAMPLE CHECK SHEET IS
    CHOCKING 5 OIL/COPPER CHIPS /GREASE 3 2 30 NOT REQUIRED NA NA
    IMPLEMENTED
    PROBLEM INSIDE THE TUBE.

    FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    FORMING DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED NA NA
    PARTS IMPARTED
    WEAR & TEAR OF TOOLS 5 TOOL HISTORY CARD IS IMPLEMENTED 2 100 NOT REQUIRED NA NA
    PRESSURE GAUGE DEPLOYED AND
    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED NA NA
    IMPLEMENTED
    IMPROPER IMPROPER SETTING OF MC & M/C SET UP BY CNC TRAINED OPERATOR
    FITMENT PROBLEM 10 YC 3 2 60 NOT REQUIRED NA NA
    DIMENSIONING FIXTURE & VERIFIED BY PROD SUP

    SPECIFIED MANDREL NOT TRAINING IS IMPARTED & FIRST OF


    3 1 30 NOT REQUIRED NA NA
    MANUAL / USED SAMPLE CHECK SHEET IS IMPLEMENTED
    CNC BENDING
    PROPERLY PLACING OF BENDED PART
    APPERANCE NG
    DENTS/ SCRATCHES/ IMPROPER HANDLING/ INTO TROLLY AS PER STANDARD / FIRST
    DENTS/SCRATCHES/ 5 YS 4 4 80 NOT REQUIRED NA NA
    PINCH DEFECTS IN DIE OFF SAMPLE CHECK SHEET IS
    PINCHES
    IMPLEMENTED

    EXTERNAL PARTICLES TCE SOLUTION CHANGE FREQUENCY IS


    T.C.E.
    IMPROPER CLEANING BRAZING PROBLEM 6 OIL/COPPER CHIPS /GREASE 2 DEFINED AS PER NO.OF PIECES WASHED 2 24 NOT REQUIRED NA NA
    CLEANING
    OUTSIDE THE TUBE. & MONITORING SHEET IS MPLEMENTED

    FULL/PARTIALLY EXTERNAL PARTICLES


    TCE SOLUTION CHANGE FREQUENCY IS
    CHOCKING 6 OIL/COPPER CHIPS /GREASE 2 2 24 NOT REQUIRED NA NA
    DEFINED AS PER NO.OF PIECES WASHED.
    PROBLEM INSIDE THE TUBE.

    IMPROPER COPPER CHIPS/EXTERNAL


    CHOCKING BLOWING PRESSURE STD (5-6 KG/CM2) &
    N2 BLOWING /INSUFFICIENT N2 7 PARTICLES REMAIN INSIDE 3 2 42 NOT REQUIRED NA NA
    PROBLEM TIME (5-10 SEC/PCS ) HAS BEEN SET UP
    FLUSHING TUBE

    MOISTURE PRESENT IN THE BLOWING PRESSURE STD (5-6 KG/CM2) &


    FUCTIONING NOT OK 7 3 2 42 NOT REQUIRED NA NA
    TUBE TIME (5-10 SEC/PCS ) HAS BEEN SET UP

    IMPROPER PERIODICALLY TRAINING PROVIDED TO ONLY TRAINED OPERATOR MUST


    FINAL FITMENT FITMENT PROBLEM 8 NEGLEGANCY OF OPERATOR 3 3 72 NA NA
    CHECKING/FITMENT OPERATOR. PERFORM THIS PROCESS
    WEAR & TEAR OF FITMENT PERIODICALLY JIG VERIFICATION IS
    3 2 48 NOT REQUIRED NA NA
    ZIG IMPLEMENTED
    PACKING STANDARD IS DISPLAYED AND
    PACKING/ IMPROPER SHORTAGE/EXCESS PACKING NOT DONE AS PER
    10 YC 3 PERIODICALLY BRAINSTORMING IS 2 60 NOT REQUIRED NA NA
    DISPATCH PACKING/DISPATCH OF MATERIAL STANDARD
    IMPARTED

    PACKING STANDARD IS DISPLAYED AND


    WRONG PACKING DONE DUE
    FITMENT PROBLEM 10 YC 4 PERIODICALLY BRAINSTORMING IS 2 80 NOT REQUIRED NA NA
    TO NEGLEGANCY OF OPT
    IMPARTED

    PERIODICALLY BRAINSTORMING OF
    NEGLENGACY OF PACKING
    MIXING PROBLEM 10 YC 4 OPERATORS & REVERIFICATION BY QC 2 80 NOT REQUIRED NA NA
    OPERATOR
    SUP BEFORE DISPATCH

    NO ACTION RECOMMENDED IF RPN<100


    ACTION RECOMMENDED IF RPN>=150
    IMMEDIATE ACTION IF RPN>150
    RECOMMENDED
    Prepared By: Checked By: Approved BY:

    Page 26 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/25-11-14
    Part name-Discharge pipe Part Code-3P386959-1

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN

    RISK PN
    STEP/INPUT MODE EFFECTS

    CLASS
    LENGTH
    FITMENT PROBLEM 10 YC IMPROPER SETTING OF M/C 4 M/C SET UP BY LINE SUPERVISOR 1 40 NOT REQUIRED NA NA
    SHORT/EXCESS
    IMPROPER SETTING OF FIRST OF SAMPLE CHECK SHEET IS
    3 1 30 NOT REQUIRED NA NA
    GUIDE ROLLER IMPLEMENTED.
    CUTTING
    APPERANCE NG
    FIRST OF SAMPLE CHECK SHEET AND
    VISUAL DEFFECT DENTS/SCRATCHES/ 5 YS DEFECTS IN CUTTING M/C DIE 4 2 40 NOT REQUIRED NA NA
    VISUAL INSPECTION IS IMPLEMENTED
    PINCHES
    WEAR & TEAR OF DIE 3 TOOL HISTORY CARD IMPLEMENTED 2 30 NOT REQUIRED NA NA
    EXTERNAL PARTICLES
    IMPROPER CLEANING FIRST OF SAMPLE CHECK SHEET IS
    DEBURRING BRAZING PROBLEM 4 OIL/COPPER CHIPS /GREASE 4 2 32 NOT REQUIRED NA NA
    OF TUBE ENDS IMPLEMENTED
    OUTSIDE THE TUBE.

    FULL/PARTIALLY EXTERNAL PARTICLES


    FIRST OF SAMPLE CHECK SHEET IS
    CHOCKING 5 OIL/COPPER CHIPS /GREASE 3 2 30 NOT REQUIRED NA NA
    IMPLEMENTED
    PROBLEM INSIDE THE TUBE.

    FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    FORMING DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED NA NA
    PARTS IMPARTED
    WEAR & TEAR OF TOOLS 5 TOOL HISTORY CARD IS IMPLEMENTED 2 100 NOT REQUIRED NA NA
    PRESSURE GAUGE DEPLOYED AND
    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED NA NA
    IMPLEMENTED
    IMPROPER IMPROPER SETTING OF MC & M/C SET UP BY CNC TRAINED OPERATOR
    FITMENT PROBLEM 10 YC 3 2 60 NOT REQUIRED NA NA
    DIMENSIONING FIXTURE & VERIFIED BY PROD SUP

    SPECIFIED MANDREL NOT TRAINING IS IMPARTED & FIRST OF


    3 1 30 NOT REQUIRED NA NA
    MANUAL / USED SAMPLE CHECK SHEET IS IMPLEMENTED
    CNC BENDING
    PROPERLY PLACING OF BENDED PART
    APPERANCE NG
    DENTS/ SCRATCHES/ IMPROPER HANDLING/ INTO TROLLY AS PER STANDARD / FIRST
    DENTS/SCRATCHES/ 5 YS 4 4 80 NOT REQUIRED NA NA
    PINCH DEFECTS IN DIE OFF SAMPLE CHECK SHEET IS
    PINCHES
    IMPLEMENTED

    EXTERNAL PARTICLES TCE SOLUTION CHANGE FREQUENCY IS


    T.C.E.
    IMPROPER CLEANING BRAZING PROBLEM 6 OIL/COPPER CHIPS /GREASE 2 DEFINED AS PER NO.OF PIECES WASHED 2 24 NOT REQUIRED NA NA
    CLEANING
    OUTSIDE THE TUBE. & MONITORING SHEET IS MPLEMENTED

    FULL/PARTIALLY EXTERNAL PARTICLES


    TCE SOLUTION CHANGE FREQUENCY IS
    CHOCKING 6 OIL/COPPER CHIPS /GREASE 2 2 24 NOT REQUIRED NA NA
    DEFINED AS PER NO.OF PIECES WASHED.
    PROBLEM INSIDE THE TUBE.

    IMPROPER COPPER CHIPS/EXTERNAL


    CHOCKING BLOWING PRESSURE STD (5-6 KG/CM2) &
    N2 BLOWING /INSUFFICIENT N2 7 PARTICLES REMAIN INSIDE 3 2 42 NOT REQUIRED NA NA
    PROBLEM TIME (5-10 SEC/PCS ) HAS BEEN SET UP
    FLUSHING TUBE

    MOISTURE PRESENT IN THE BLOWING PRESSURE STD (5-6 KG/CM2) &


    FUCTIONING NOT OK 7 3 2 42 NOT REQUIRED NA NA
    TUBE TIME (5-10 SEC/PCS ) HAS BEEN SET UP

    IMPROPER PERIODICALLY TRAINING PROVIDED TO ONLY TRAINED OPERATOR MUST


    FINAL FITMENT FITMENT PROBLEM 8 NEGLEGANCY OF OPERATOR 3 3 72 NA NA
    CHECKING/FITMENT OPERATOR. PERFORM THIS PROCESS
    WEAR & TEAR OF FITMENT PERIODICALLY JIG VERIFICATION IS
    3 2 48 NOT REQUIRED NA NA
    ZIG IMPLEMENTED
    PACKING STANDARD IS DISPLAYED AND
    PACKING/ IMPROPER SHORTAGE/EXCESS PACKING NOT DONE AS PER
    10 YC 3 PERIODICALLY BRAINSTORMING IS 2 60 NOT REQUIRED NA NA
    DISPATCH PACKING/DISPATCH OF MATERIAL STANDARD
    IMPARTED

    PACKING STANDARD IS DISPLAYED AND


    WRONG PACKING DONE DUE
    FITMENT PROBLEM 10 YC 4 PERIODICALLY BRAINSTORMING IS 2 80 NOT REQUIRED NA NA
    TO NEGLEGANCY OF OPT
    IMPARTED

    PERIODICALLY BRAINSTORMING OF
    NEGLENGACY OF PACKING
    MIXING PROBLEM 10 YC 4 OPERATORS & REVERIFICATION BY QC 2 80 NOT REQUIRED NA NA
    OPERATOR
    SUP BEFORE DISPATCH

    NO ACTION RECOMMENDED IF RPN<100


    ACTION RECOMMENDED IF RPN>=150
    IMMEDIATE ACTION IF RPN>150
    RECOMMENDED
    Prepared By: Checked By: Approved BY:

    Page 27 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/25-11-14
    Part name-Discharge pipe Part Code-3P379590-1

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN

    RISK PN
    STEP/INPUT MODE EFFECTS

    CLASS
    LENGTH
    FITMENT PROBLEM 10 YC IMPROPER SETTING OF M/C 4 M/C SET UP BY LINE SUPERVISOR 1 40 NOT REQUIRED NA NA
    SHORT/EXCESS
    IMPROPER SETTING OF FIRST OF SAMPLE CHECK SHEET IS
    3 1 30 NOT REQUIRED NA NA
    GUIDE ROLLER IMPLEMENTED.
    CUTTING
    APPERANCE NG
    FIRST OF SAMPLE CHECK SHEET AND
    VISUAL DEFFECT DENTS/SCRATCHES/ 5 YS DEFECTS IN CUTTING M/C DIE 4 2 40 NOT REQUIRED NA NA
    VISUAL INSPECTION IS IMPLEMENTED
    PINCHES
    WEAR & TEAR OF DIE 3 TOOL HISTORY CARD IMPLEMENTED 2 30 NOT REQUIRED NA NA
    EXTERNAL PARTICLES
    IMPROPER CLEANING FIRST OF SAMPLE CHECK SHEET IS
    DEBURRING BRAZING PROBLEM 4 OIL/COPPER CHIPS /GREASE 4 2 32 NOT REQUIRED NA NA
    OF TUBE ENDS IMPLEMENTED
    OUTSIDE THE TUBE.

    FULL/PARTIALLY EXTERNAL PARTICLES


    FIRST OF SAMPLE CHECK SHEET IS
    CHOCKING 5 OIL/COPPER CHIPS /GREASE 3 2 30 NOT REQUIRED NA NA
    IMPLEMENTED
    PROBLEM INSIDE THE TUBE.

    FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    FORMING DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED NA NA
    PARTS IMPARTED
    WEAR & TEAR OF TOOLS 5 TOOL HISTORY CARD IS IMPLEMENTED 2 100 NOT REQUIRED NA NA
    PRESSURE GAUGE DEPLOYED AND
    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED NA NA
    IMPLEMENTED
    IMPROPER IMPROPER SETTING OF MC & M/C SET UP BY CNC TRAINED OPERATOR
    FITMENT PROBLEM 10 YC 3 2 60 NOT REQUIRED NA NA
    DIMENSIONING FIXTURE & VERIFIED BY PROD SUP

    SPECIFIED MANDREL NOT TRAINING IS IMPARTED & FIRST OF


    3 1 30 NOT REQUIRED NA NA
    MANUAL / USED SAMPLE CHECK SHEET IS IMPLEMENTED
    CNC BENDING
    PROPERLY PLACING OF BENDED PART
    APPERANCE NG
    DENTS/ SCRATCHES/ IMPROPER HANDLING/ INTO TROLLY AS PER STANDARD / FIRST
    DENTS/SCRATCHES/ 5 YS 4 4 80 NOT REQUIRED NA NA
    PINCH DEFECTS IN DIE OFF SAMPLE CHECK SHEET IS
    PINCHES
    IMPLEMENTED

    EXTERNAL PARTICLES TCE SOLUTION CHANGE FREQUENCY IS


    T.C.E.
    IMPROPER CLEANING BRAZING PROBLEM 6 OIL/COPPER CHIPS /GREASE 2 DEFINED AS PER NO.OF PIECES WASHED 2 24 NOT REQUIRED NA NA
    CLEANING
    OUTSIDE THE TUBE. & MONITORING SHEET IS MPLEMENTED

    FULL/PARTIALLY EXTERNAL PARTICLES


    TCE SOLUTION CHANGE FREQUENCY IS
    CHOCKING 6 OIL/COPPER CHIPS /GREASE 2 2 24 NOT REQUIRED NA NA
    DEFINED AS PER NO.OF PIECES WASHED.
    PROBLEM INSIDE THE TUBE.

    IMPROPER COPPER CHIPS/EXTERNAL


    CHOCKING BLOWING PRESSURE STD (5-6 KG/CM2) &
    N2 BLOWING /INSUFFICIENT N2 7 PARTICLES REMAIN INSIDE 3 2 42 NOT REQUIRED NA NA
    PROBLEM TIME (5-10 SEC/PCS ) HAS BEEN SET UP
    FLUSHING TUBE

    MOISTURE PRESENT IN THE BLOWING PRESSURE STD (5-6 KG/CM2) &


    FUCTIONING NOT OK 7 3 2 42 NOT REQUIRED NA NA
    TUBE TIME (5-10 SEC/PCS ) HAS BEEN SET UP

    IMPROPER PERIODICALLY TRAINING PROVIDED TO ONLY TRAINED OPERATOR MUST


    FINAL FITMENT FITMENT PROBLEM 8 NEGLEGANCY OF OPERATOR 3 3 72 NA NA
    CHECKING/FITMENT OPERATOR. PERFORM THIS PROCESS
    WEAR & TEAR OF FITMENT PERIODICALLY JIG VERIFICATION IS
    3 2 48 NOT REQUIRED NA NA
    ZIG IMPLEMENTED
    PACKING STANDARD IS DISPLAYED AND
    PACKING/ IMPROPER SHORTAGE/EXCESS PACKING NOT DONE AS PER
    10 YC 3 PERIODICALLY BRAINSTORMING IS 2 60 NOT REQUIRED NA NA
    DISPATCH PACKING/DISPATCH OF MATERIAL STANDARD
    IMPARTED

    PACKING STANDARD IS DISPLAYED AND


    WRONG PACKING DONE DUE
    FITMENT PROBLEM 10 YC 4 PERIODICALLY BRAINSTORMING IS 2 80 NOT REQUIRED NA NA
    TO NEGLEGANCY OF OPT
    IMPARTED

    PERIODICALLY BRAINSTORMING OF
    NEGLENGACY OF PACKING
    MIXING PROBLEM 10 YC 4 OPERATORS & REVERIFICATION BY QC 2 80 NOT REQUIRED NA NA
    OPERATOR
    SUP BEFORE DISPATCH

    NO ACTION RECOMMENDED IF RPN<100


    ACTION RECOMMENDED IF RPN>=150
    IMMEDIATE ACTION IF RPN>150
    RECOMMENDED
    Prepared By: Checked By: Approved BY:

    Page 28 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/25-11-14

    Part name-Discharge pipe assy Part Code-3P382069-1A

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    LENGTH
    FITMENT PROBLEM 10 YC IMPROPER SETTING OF M/C 4 M/C SET UP BY LINE SUPERVISOR 1 40 NOT REQUIRED NA NA
    SHORT/EXCESS
    IMPROPER SETTING OF FIRST OF SAMPLE CHECK SHEET IS
    3 1 30 NOT REQUIRED NA NA
    GUIDE ROLLER IMPLEMENTED.
    CUTTING
    APPERANCE NG
    FIRST OF SAMPLE CHECK SHEET AND
    VISUAL DEFFECT DENTS/SCRATCHES/ 5 YS DEFECTS IN CUTTING M/C DIE 4 2 40 NOT REQUIRED NA NA
    VISUAL INSPECTION IS IMPLEMENTED
    PINCHES
    WEAR & TEAR OF DIE 3 TOOL HISTORY CARD IMPLEMENTED 2 30 NOT REQUIRED NA NA
    EXTERNAL PARTICLES
    IMPROPER CLEANING FIRST OF SAMPLE CHECK SHEET IS
    DEBURRING BRAZING PROBLEM 4 OIL/COPPER CHIPS /GREASE 4 2 32 NOT REQUIRED NA NA
    OF TUBE ENDS IMPLEMENTED
    OUTSIDE THE TUBE.

    FULL/PARTIALLY EXTERNAL PARTICLES


    FIRST OF SAMPLE CHECK SHEET IS
    CHOCKING 5 OIL/COPPER CHIPS /GREASE 3 2 30 NOT REQUIRED NA NA
    IMPLEMENTED
    PROBLEM INSIDE THE TUBE.

    FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    FORMING DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED NA NA
    PARTS IMPARTED
    WEAR & TEAR OF TOOLS 5 TOOL HISTORY CARD IS IMPLEMENTED 2 100 NOT REQUIRED NA NA
    PRESSURE GAUGE DEPLOYED AND
    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED NA NA
    IMPLEMENTED
    IMPROPER IMPROPER SETTING OF MC & M/C SET UP BY CNC TRAINED OPERATOR
    FITMENT PROBLEM 10 YC 3 2 60 NOT REQUIRED NA NA
    DIMENSIONING FIXTURE & VERIFIED BY PROD SUP

    SPECIFIED MANDREL NOT TRAINING IS IMPARTED & FIRST OF


    3 1 30 NOT REQUIRED NA NA
    MANUAL / USED SAMPLE CHECK SHEET IS IMPLEMENTED
    CNC BENDING
    PROPERLY PLACING OF BENDED PART
    APPERANCE NG
    DENTS/ SCRATCHES/ IMPROPER HANDLING/ INTO TROLLY AS PER STANDARD / FIRST
    DENTS/SCRATCHES/ 5 YS 4 4 80 NOT REQUIRED NA NA
    PINCH DEFECTS IN DIE OFF SAMPLE CHECK SHEET IS
    PINCHES
    IMPLEMENTED

    EXTERNAL PARTICLES TCE SOLUTION CHANGE FREQUENCY IS


    T.C.E.
    IMPROPER CLEANING BRAZING PROBLEM 6 OIL/COPPER CHIPS /GREASE 2 DEFINED AS PER NO.OF PIECES WASHED 2 24 NOT REQUIRED NA NA
    CLEANING
    OUTSIDE THE TUBE. & MONITORING SHEET IS MPLEMENTED

    FULL/PARTIALLY EXTERNAL PARTICLES


    TCE SOLUTION CHANGE FREQUENCY IS
    CHOCKING 6 OIL/COPPER CHIPS /GREASE 2 2 24 NOT REQUIRED NA NA
    DEFINED AS PER NO.OF PIECES WASHED.
    PROBLEM INSIDE THE TUBE.

    IMPROPER COPPER CHIPS/EXTERNAL


    CHOCKING BLOWING PRESSURE STD (5-6 KG/CM2) &
    N2 BLOWING /INSUFFICIENT N2 7 PARTICLES REMAIN INSIDE 3 2 42 NOT REQUIRED NA NA
    PROBLEM TIME (5-10 SEC/PCS ) HAS BEEN SET UP
    FLUSHING TUBE

    MOISTURE PRESENT IN THE BLOWING PRESSURE STD (5-6 KG/CM2) &


    FUCTIONING NOT OK 7 3 2 42 NOT REQUIRED NA NA
    TUBE TIME (5-10 SEC/PCS ) HAS BEEN SET UP

    PROD
    FIXTURE VERIFICATION wrt FINAL
    IMPROPER ALL FIXTURE HAS BEEN MARKED & COLOR SUP FIXTURE VERIFICATION & FIRST OFF
    BRAZING FITMENT PROBLEM 10 YC BRAZING FIXTURE NOT OK 4 4 160 FITMENT JIG TO BE IMPLEMENTED 10 3 3 90
    DIMENSIONING CODED SUDESH/ SAMPLE SHEET IMPLEMENTED
    BEFORE STARTING THE PRODN
    TEJPAL

    ONLY TRAINED OPERATOR TO BE


    PROD ONLY CERTIFIED BRAZER IS ALLOWED
    ONLY SKILLED & SEMISKILLED ALLOWED TO BRAZE & PERIODICALLY
    IMPROPER BRAZING SUP TO BRAZE & BRAZER TRAINING HAS
    LEAKAGE/CHOCKING 10 YC UNTRAINED OPERATOR 4 OPERATORS ARE PERFORMING BRAZING 4 160 TRAINING SYSTEM TO BE 10 3 3 90
    LESS/EXCESS SUDESH/ BEEN IMPARTED TO SEMI SKILLED
    OPERATION. IMPLEMENTED TO SEMI SKILLED OPT
    TEJPAL BRAZER
    TO MAKE THEM TRAINED

    QC
    RED BIN LOCATION MUST BE UNDER RED BIN LOCATION IS DEFINED, ITS
    ENGG/
    SKIPPING OF LEAK PCS & TABLE & LEAKE PORTION TO BE RED USAGE TRAINING HAS BEEN IMPARTED
    LEAK TESTING IMPROPER TESTING GAS LEAKAGE 10 YC 4 RED BIN SYSTEM IS IMPLEMENTED 3 120 SUP 10 3 3 90
    MIXED UP WITH OK PCS MARKED & TRAINING HOW TO USE RED & RED MARKING AT THE LEAK
    MANOJ/
    BIN TO BE IMPARTED PORTION IS IMPLEMENTED
    SANJAY

    STRICTLY RECOMMENDED HIGHLY


    TRAINED OPERATOR TO PERFORM ONLY CERTIFIED LEAKAGE TESTING
    QC
    THIS OPERATION AND PERIODICALLY OPERATOR IS ALLOWED TO TEST &
    ENGG/
    IMPROPER PRESSURE & TRAINING TO THEM & SEMI-SKILLED PERIODICALLY TRAINING IS IMPARTED.
    5 TRAINED OPERATOR APPOINTED 4 200 SUP 10 3 3 90
    TESTING TIME OPERATOR MUST BE IMPARTED & AIR PRESSURE GUAGE IS LOCATED AT
    MANOJ/
    PRESSURE GAUGE MUST BE LOCATED EACH STATION AND MONITORING
    SANJAY
    ON EACH STATION & MONITORING SHEET IS IMPLEMENTED
    MUST BE DONE

    QC
    MINERAL OR RO-WATER TO BE USED ENGG/ RO WATER IS IMPLEMENTED &
    DIRECT TAP WATER IS USED & CHANGE
    CONDITION OF WATER 4 4 160 AND WATER CHANGE FREQUENCY TO SUP CHANGE FREQUENCY IS VISUAL 10 3 3 90
    FREQUENCY IS BASED ON VISUAL
    BE REVIEWED MANOJ/ BASED
    SANJAY

    100% CHOCK TEST TO BE DONE WITH PROD


    CHOCK SKIPPING OF CHOCKED PCS WATER ANOTHER SIDE & MUST BE SUP 100% CHOCK TEST IS IMPLEMENTED
    IMPROPER TESTING GAS FLOW STOP 10 YC 4 NO CHOCK TEST IS PERFORMED 4 160 10 3 3 90
    TESTING & MIXED UP WITH OK PCS CONTROLLED BY CODING/MARKING ON SUDESH/ WITH MARKING
    EACH PART TEJPAL

    IMPROPER
    IMPROPER AIR MOISTURE PRESENT IN THE PRESSURE GUAGE & AIR BLOWING TIME
    WATER DRYING FUNCTIONNING OF 7 3 2 42 NOT REQUIRED NA NA
    BLOWING TUBE PERIOD MAINTAINED
    COMPRESSOR
    MOISTURE PRESENT IN THE DAILY MONITORING PROCESS CHECK
    RUSTING OF TUBES 5 3 2 30 NOT REQUIRED NA NA
    TUBE SHEET HAS BEN IMPLEMENTED.
    IMPROPER PERIODICALLY TRAINING PROVIDED TO ONLY TRAINED OPERATOR MUST
    FINAL FITMENT FITMENT PROBLEM 8 NEGLEGANCY OF OPERATOR 3 3 72 NA NA
    CHECKING/FITMENT OPERATOR. PERFORM THIS PROCESS
    WEAR & TEAR OF FITMENT PERIODICALLY JIG VERIFICATION IS
    3 2 48 NOT REQUIRED NA NA
    ZIG IMPLEMENTED
    PACKING STANDARD IS DISPLAYED AND
    PACKING/ IMPROPER SHORTAGE/EXCESS PACKING NOT DONE AS PER
    10 YC 3 PERIODICALLY BRAINSTORMING IS 2 60 NOT REQUIRED NA NA
    DISPATCH PACKING/DISPATCH OF MATERIAL STANDARD
    IMPARTED

    PACKING STANDARD IS DISPLAYED AND


    WRONG PACKING DONE DUE
    FITMENT PROBLEM 10 YC 4 PERIODICALLY BRAINSTORMING IS 2 80 NOT REQUIRED NA NA
    TO NEGLEGANCY OF OPT
    IMPARTED

    PERIODICALLY BRAINSTORMING OF
    NEGLENGACY OF PACKING
    MIXING PROBLEM 10 YC 4 OPERATORS & REVERIFICATION BY QC 2 80 NOT REQUIRED NA NA
    OPERATOR
    SUP BEFORE DISPATCH

    NO ACTION RECOMMENDED IF RPN<100


    ACTION RECOMMENDED IF RPN>=150
    IMMEDIATE ACTION IF RPN>150
    RECOMMENDED

    Page 29 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/25-11-14

    Part name-Discharge pipe assy Part Code-3P382069-1A

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    Prepared By: Checked By: Approved BY:

    Page 30 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/25-11-14
    Part name-Discharge pipe Part Code-3P387304-1A

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN

    RISK PN
    STEP/INPUT MODE EFFECTS

    CLASS
    LENGTH
    FITMENT PROBLEM 10 YC IMPROPER SETTING OF M/C 4 M/C SET UP BY LINE SUPERVISOR 1 40 NOT REQUIRED NA NA
    SHORT/EXCESS
    IMPROPER SETTING OF FIRST OF SAMPLE CHECK SHEET IS
    3 1 30 NOT REQUIRED NA NA
    GUIDE ROLLER IMPLEMENTED.
    CUTTING
    APPERANCE NG
    FIRST OF SAMPLE CHECK SHEET AND
    VISUAL DEFFECT DENTS/SCRATCHES/ 5 YS DEFECTS IN CUTTING M/C DIE 4 2 40 NOT REQUIRED NA NA
    VISUAL INSPECTION IS IMPLEMENTED
    PINCHES
    WEAR & TEAR OF DIE 3 TOOL HISTORY CARD IMPLEMENTED 2 30 NOT REQUIRED NA NA
    EXTERNAL PARTICLES
    IMPROPER CLEANING FIRST OF SAMPLE CHECK SHEET IS
    DEBURRING BRAZING PROBLEM 4 OIL/COPPER CHIPS /GREASE 4 2 32 NOT REQUIRED NA NA
    OF TUBE ENDS IMPLEMENTED
    OUTSIDE THE TUBE.

    FULL/PARTIALLY EXTERNAL PARTICLES


    FIRST OF SAMPLE CHECK SHEET IS
    CHOCKING 5 OIL/COPPER CHIPS /GREASE 3 2 30 NOT REQUIRED NA NA
    IMPLEMENTED
    PROBLEM INSIDE THE TUBE.

    FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    FORMING DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED NA NA
    PARTS IMPARTED
    WEAR & TEAR OF TOOLS 5 TOOL HISTORY CARD IS IMPLEMENTED 2 100 NOT REQUIRED NA NA
    PRESSURE GAUGE DEPLOYED AND
    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED NA NA
    IMPLEMENTED
    IMPROPER IMPROPER SETTING OF MC & M/C SET UP BY CNC TRAINED OPERATOR
    FITMENT PROBLEM 10 YC 3 2 60 NOT REQUIRED NA NA
    DIMENSIONING FIXTURE & VERIFIED BY PROD SUP

    SPECIFIED MANDREL NOT TRAINING IS IMPARTED & FIRST OF


    3 1 30 NOT REQUIRED NA NA
    MANUAL / USED SAMPLE CHECK SHEET IS IMPLEMENTED
    CNC BENDING
    PROPERLY PLACING OF BENDED PART
    APPERANCE NG
    DENTS/ SCRATCHES/ IMPROPER HANDLING/ INTO TROLLY AS PER STANDARD / FIRST
    DENTS/SCRATCHES/ 5 YS 4 4 80 NOT REQUIRED NA NA
    PINCH DEFECTS IN DIE OFF SAMPLE CHECK SHEET IS
    PINCHES
    IMPLEMENTED

    EXTERNAL PARTICLES TCE SOLUTION CHANGE FREQUENCY IS


    T.C.E.
    IMPROPER CLEANING BRAZING PROBLEM 6 OIL/COPPER CHIPS /GREASE 2 DEFINED AS PER NO.OF PIECES WASHED 2 24 NOT REQUIRED NA NA
    CLEANING
    OUTSIDE THE TUBE. & MONITORING SHEET IS MPLEMENTED

    FULL/PARTIALLY EXTERNAL PARTICLES


    TCE SOLUTION CHANGE FREQUENCY IS
    CHOCKING 6 OIL/COPPER CHIPS /GREASE 2 2 24 NOT REQUIRED NA NA
    DEFINED AS PER NO.OF PIECES WASHED.
    PROBLEM INSIDE THE TUBE.

    IMPROPER COPPER CHIPS/EXTERNAL


    CHOCKING BLOWING PRESSURE STD (5-6 KG/CM2) &
    N2 BLOWING /INSUFFICIENT N2 7 PARTICLES REMAIN INSIDE 3 2 42 NOT REQUIRED NA NA
    PROBLEM TIME (5-10 SEC/PCS ) HAS BEEN SET UP
    FLUSHING TUBE

    MOISTURE PRESENT IN THE BLOWING PRESSURE STD (5-6 KG/CM2) &


    FUCTIONING NOT OK 7 3 2 42 NOT REQUIRED NA NA
    TUBE TIME (5-10 SEC/PCS ) HAS BEEN SET UP

    IMPROPER PERIODICALLY TRAINING PROVIDED TO ONLY TRAINED OPERATOR MUST


    FINAL FITMENT FITMENT PROBLEM 8 NEGLEGANCY OF OPERATOR 3 3 72 NA NA
    CHECKING/FITMENT OPERATOR. PERFORM THIS PROCESS
    WEAR & TEAR OF FITMENT PERIODICALLY JIG VERIFICATION IS
    3 2 48 NOT REQUIRED NA NA
    ZIG IMPLEMENTED
    PACKING STANDARD IS DISPLAYED AND
    PACKING/ IMPROPER SHORTAGE/EXCESS PACKING NOT DONE AS PER
    10 YC 3 PERIODICALLY BRAINSTORMING IS 2 60 NOT REQUIRED NA NA
    DISPATCH PACKING/DISPATCH OF MATERIAL STANDARD
    IMPARTED

    PACKING STANDARD IS DISPLAYED AND


    WRONG PACKING DONE DUE
    FITMENT PROBLEM 10 YC 4 PERIODICALLY BRAINSTORMING IS 2 80 NOT REQUIRED NA NA
    TO NEGLEGANCY OF OPT
    IMPARTED

    PERIODICALLY BRAINSTORMING OF
    NEGLENGACY OF PACKING
    MIXING PROBLEM 10 YC 4 OPERATORS & REVERIFICATION BY QC 2 80 NOT REQUIRED NA NA
    OPERATOR
    SUP BEFORE DISPATCH

    NO ACTION RECOMMENDED IF RPN<100


    ACTION RECOMMENDED IF RPN>=150
    IMMEDIATE ACTION IF RPN>150
    RECOMMENDED
    Prepared By: Checked By: Approved BY:

    Page 31 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/25-11-14
    Part name-Plate finned coil outlet pipe(1) Part Code-3P380451-1

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN

    RISK PN
    STEP/INPUT MODE EFFECTS

    CLASS
    LENGTH
    FITMENT PROBLEM 10 YC IMPROPER SETTING OF M/C 4 M/C SET UP BY LINE SUPERVISOR 1 40 NOT REQUIRED NA NA
    SHORT/EXCESS
    IMPROPER SETTING OF FIRST OF SAMPLE CHECK SHEET IS
    3 1 30 NOT REQUIRED NA NA
    GUIDE ROLLER IMPLEMENTED.
    CUTTING
    APPERANCE NG
    FIRST OF SAMPLE CHECK SHEET AND
    VISUAL DEFFECT DENTS/SCRATCHES/ 5 YS DEFECTS IN CUTTING M/C DIE 4 2 40 NOT REQUIRED NA NA
    VISUAL INSPECTION IS IMPLEMENTED
    PINCHES
    WEAR & TEAR OF DIE 3 TOOL HISTORY CARD IMPLEMENTED 2 30 NOT REQUIRED NA NA
    EXTERNAL PARTICLES
    IMPROPER CLEANING FIRST OF SAMPLE CHECK SHEET IS
    DEBURRING BRAZING PROBLEM 4 OIL/COPPER CHIPS /GREASE 4 2 32 NOT REQUIRED NA NA
    OF TUBE ENDS IMPLEMENTED
    OUTSIDE THE TUBE.

    FULL/PARTIALLY EXTERNAL PARTICLES


    FIRST OF SAMPLE CHECK SHEET IS
    CHOCKING 5 OIL/COPPER CHIPS /GREASE 3 2 30 NOT REQUIRED NA NA
    IMPLEMENTED
    PROBLEM INSIDE THE TUBE.

    FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    FORMING DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED NA NA
    PARTS IMPARTED
    WEAR & TEAR OF TOOLS 5 TOOL HISTORY CARD IS IMPLEMENTED 2 100 NOT REQUIRED NA NA
    PRESSURE GAUGE DEPLOYED AND
    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED NA NA
    IMPLEMENTED
    IMPROPER IMPROPER SETTING OF MC & M/C SET UP BY CNC TRAINED OPERATOR
    FITMENT PROBLEM 10 YC 3 2 60 NOT REQUIRED NA NA
    DIMENSIONING FIXTURE & VERIFIED BY PROD SUP

    SPECIFIED MANDREL NOT TRAINING IS IMPARTED & FIRST OF


    3 1 30 NOT REQUIRED NA NA
    MANUAL / USED SAMPLE CHECK SHEET IS IMPLEMENTED
    CNC BENDING
    PROPERLY PLACING OF BENDED PART
    APPERANCE NG
    DENTS/ SCRATCHES/ IMPROPER HANDLING/ INTO TROLLY AS PER STANDARD / FIRST
    DENTS/SCRATCHES/ 5 YS 4 4 80 NOT REQUIRED NA NA
    PINCH DEFECTS IN DIE OFF SAMPLE CHECK SHEET IS
    PINCHES
    IMPLEMENTED

    EXTERNAL PARTICLES TCE SOLUTION CHANGE FREQUENCY IS


    T.C.E.
    IMPROPER CLEANING BRAZING PROBLEM 6 OIL/COPPER CHIPS /GREASE 2 DEFINED AS PER NO.OF PIECES WASHED 2 24 NOT REQUIRED NA NA
    CLEANING
    OUTSIDE THE TUBE. & MONITORING SHEET IS MPLEMENTED

    FULL/PARTIALLY EXTERNAL PARTICLES


    TCE SOLUTION CHANGE FREQUENCY IS
    CHOCKING 6 OIL/COPPER CHIPS /GREASE 2 2 24 NOT REQUIRED NA NA
    DEFINED AS PER NO.OF PIECES WASHED.
    PROBLEM INSIDE THE TUBE.

    IMPROPER COPPER CHIPS/EXTERNAL


    CHOCKING BLOWING PRESSURE STD (5-6 KG/CM2) &
    N2 BLOWING /INSUFFICIENT N2 7 PARTICLES REMAIN INSIDE 3 2 42 NOT REQUIRED NA NA
    PROBLEM TIME (5-10 SEC/PCS ) HAS BEEN SET UP
    FLUSHING TUBE

    MOISTURE PRESENT IN THE BLOWING PRESSURE STD (5-6 KG/CM2) &


    FUCTIONING NOT OK 7 3 2 42 NOT REQUIRED NA NA
    TUBE TIME (5-10 SEC/PCS ) HAS BEEN SET UP

    IMPROPER PERIODICALLY TRAINING PROVIDED TO ONLY TRAINED OPERATOR MUST


    FINAL FITMENT FITMENT PROBLEM 8 NEGLEGANCY OF OPERATOR 3 3 72 NA NA
    CHECKING/FITMENT OPERATOR. PERFORM THIS PROCESS
    WEAR & TEAR OF FITMENT PERIODICALLY JIG VERIFICATION IS
    3 2 48 NOT REQUIRED NA NA
    ZIG IMPLEMENTED
    PACKING STANDARD IS DISPLAYED AND
    PACKING/ IMPROPER SHORTAGE/EXCESS PACKING NOT DONE AS PER
    10 YC 3 PERIODICALLY BRAINSTORMING IS 2 60 NOT REQUIRED NA NA
    DISPATCH PACKING/DISPATCH OF MATERIAL STANDARD
    IMPARTED

    PACKING STANDARD IS DISPLAYED AND


    WRONG PACKING DONE DUE
    FITMENT PROBLEM 10 YC 4 PERIODICALLY BRAINSTORMING IS 2 80 NOT REQUIRED NA NA
    TO NEGLEGANCY OF OPT
    IMPARTED

    PERIODICALLY BRAINSTORMING OF
    NEGLENGACY OF PACKING
    MIXING PROBLEM 10 YC 4 OPERATORS & REVERIFICATION BY QC 2 80 NOT REQUIRED NA NA
    OPERATOR
    SUP BEFORE DISPATCH

    NO ACTION RECOMMENDED IF RPN<100


    ACTION RECOMMENDED IF RPN>=150
    IMMEDIATE ACTION IF RPN>150
    RECOMMENDED
    Prepared By: Checked By: Approved BY:

    Page 32 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/25-11-14

    Part name-Plate finned coil inlet pipe assy Part Code-3P379454-1

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    LENGTH
    FITMENT PROBLEM 10 YC IMPROPER SETTING OF M/C 4 M/C SET UP BY LINE SUPERVISOR 1 40 NOT REQUIRED NA NA
    SHORT/EXCESS
    IMPROPER SETTING OF FIRST OF SAMPLE CHECK SHEET IS
    3 1 30 NOT REQUIRED NA NA
    GUIDE ROLLER IMPLEMENTED.
    CUTTING
    APPERANCE NG
    FIRST OF SAMPLE CHECK SHEET AND
    VISUAL DEFFECT DENTS/SCRATCHES/ 5 YS DEFECTS IN CUTTING M/C DIE 4 2 40 NOT REQUIRED NA NA
    VISUAL INSPECTION IS IMPLEMENTED
    PINCHES
    WEAR & TEAR OF DIE 3 TOOL HISTORY CARD IMPLEMENTED 2 30 NOT REQUIRED NA NA
    EXTERNAL PARTICLES
    IMPROPER CLEANING FIRST OF SAMPLE CHECK SHEET IS
    DEBURRING BRAZING PROBLEM 4 OIL/COPPER CHIPS /GREASE 4 2 32 NOT REQUIRED NA NA
    OF TUBE ENDS IMPLEMENTED
    OUTSIDE THE TUBE.

    FULL/PARTIALLY EXTERNAL PARTICLES


    FIRST OF SAMPLE CHECK SHEET IS
    CHOCKING 5 OIL/COPPER CHIPS /GREASE 3 2 30 NOT REQUIRED NA NA
    IMPLEMENTED
    PROBLEM INSIDE THE TUBE.

    FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    FORMING DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED NA NA
    PARTS IMPARTED
    WEAR & TEAR OF TOOLS 5 TOOL HISTORY CARD IS IMPLEMENTED 2 100 NOT REQUIRED NA NA
    PRESSURE GAUGE DEPLOYED AND
    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED NA NA
    IMPLEMENTED
    IMPROPER IMPROPER SETTING OF MC & M/C SET UP BY CNC TRAINED OPERATOR
    FITMENT PROBLEM 10 YC 3 2 60 NOT REQUIRED NA NA
    DIMENSIONING FIXTURE & VERIFIED BY PROD SUP

    SPECIFIED MANDREL NOT TRAINING IS IMPARTED & FIRST OF


    3 1 30 NOT REQUIRED NA NA
    MANUAL / USED SAMPLE CHECK SHEET IS IMPLEMENTED
    CNC BENDING
    PROPERLY PLACING OF BENDED PART
    APPERANCE NG
    DENTS/ SCRATCHES/ IMPROPER HANDLING/ INTO TROLLY AS PER STANDARD / FIRST
    DENTS/SCRATCHES/ 5 YS 4 4 80 NOT REQUIRED NA NA
    PINCH DEFECTS IN DIE OFF SAMPLE CHECK SHEET IS
    PINCHES
    IMPLEMENTED

    EXTERNAL PARTICLES TCE SOLUTION CHANGE FREQUENCY IS


    T.C.E.
    IMPROPER CLEANING BRAZING PROBLEM 6 OIL/COPPER CHIPS /GREASE 2 DEFINED AS PER NO.OF PIECES WASHED 2 24 NOT REQUIRED NA NA
    CLEANING
    OUTSIDE THE TUBE. & MONITORING SHEET IS MPLEMENTED

    FULL/PARTIALLY EXTERNAL PARTICLES


    TCE SOLUTION CHANGE FREQUENCY IS
    CHOCKING 6 OIL/COPPER CHIPS /GREASE 2 2 24 NOT REQUIRED NA NA
    DEFINED AS PER NO.OF PIECES WASHED.
    PROBLEM INSIDE THE TUBE.

    IMPROPER COPPER CHIPS/EXTERNAL


    CHOCKING BLOWING PRESSURE STD (5-6 KG/CM2) &
    N2 BLOWING /INSUFFICIENT N2 7 PARTICLES REMAIN INSIDE 3 2 42 NOT REQUIRED NA NA
    PROBLEM TIME (5-10 SEC/PCS ) HAS BEEN SET UP
    FLUSHING TUBE

    MOISTURE PRESENT IN THE BLOWING PRESSURE STD (5-6 KG/CM2) &


    FUCTIONING NOT OK 7 3 2 42 NOT REQUIRED NA NA
    TUBE TIME (5-10 SEC/PCS ) HAS BEEN SET UP

    PROD
    FIXTURE VERIFICATION wrt FINAL
    IMPROPER ALL FIXTURE HAS BEEN MARKED & COLOR SUP FIXTURE VERIFICATION & FIRST OFF
    BRAZING FITMENT PROBLEM 10 YC BRAZING FIXTURE NOT OK 4 4 160 FITMENT JIG TO BE IMPLEMENTED 10 3 3 90
    DIMENSIONING CODED SUDESH/ SAMPLE SHEET IMPLEMENTED
    BEFORE STARTING THE PRODN
    TEJPAL

    ONLY TRAINED OPERATOR TO BE


    PROD ONLY CERTIFIED BRAZER IS ALLOWED
    ONLY SKILLED & SEMISKILLED ALLOWED TO BRAZE & PERIODICALLY
    IMPROPER BRAZING SUP TO BRAZE & BRAZER TRAINING HAS
    LEAKAGE/CHOCKING 10 YC UNTRAINED OPERATOR 4 OPERATORS ARE PERFORMING BRAZING 4 160 TRAINING SYSTEM TO BE 10 3 3 90
    LESS/EXCESS SUDESH/ BEEN IMPARTED TO SEMI SKILLED
    OPERATION. IMPLEMENTED TO SEMI SKILLED OPT
    TEJPAL BRAZER
    TO MAKE THEM TRAINED

    QC
    RED BIN LOCATION MUST BE UNDER RED BIN LOCATION IS DEFINED, ITS
    ENGG/
    SKIPPING OF LEAK PCS & TABLE & LEAKE PORTION TO BE RED USAGE TRAINING HAS BEEN IMPARTED
    LEAK TESTING IMPROPER TESTING GAS LEAKAGE 10 YC 4 RED BIN SYSTEM IS IMPLEMENTED 3 120 SUP 10 3 3 90
    MIXED UP WITH OK PCS MARKED & TRAINING HOW TO USE RED & RED MARKING AT THE LEAK
    MANOJ/
    BIN TO BE IMPARTED PORTION IS IMPLEMENTED
    SANJAY

    STRICTLY RECOMMENDED HIGHLY


    TRAINED OPERATOR TO PERFORM ONLY CERTIFIED LEAKAGE TESTING
    QC
    THIS OPERATION AND PERIODICALLY OPERATOR IS ALLOWED TO TEST &
    ENGG/
    IMPROPER PRESSURE & TRAINING TO THEM & SEMI-SKILLED PERIODICALLY TRAINING IS IMPARTED.
    5 TRAINED OPERATOR APPOINTED 4 200 SUP 10 3 3 90
    TESTING TIME OPERATOR MUST BE IMPARTED & AIR PRESSURE GUAGE IS LOCATED AT
    MANOJ/
    PRESSURE GAUGE MUST BE LOCATED EACH STATION AND MONITORING
    SANJAY
    ON EACH STATION & MONITORING SHEET IS IMPLEMENTED
    MUST BE DONE

    QC
    MINERAL OR RO-WATER TO BE USED ENGG/ RO WATER IS IMPLEMENTED &
    DIRECT TAP WATER IS USED & CHANGE
    CONDITION OF WATER 4 4 160 AND WATER CHANGE FREQUENCY TO SUP CHANGE FREQUENCY IS VISUAL 10 3 3 90
    FREQUENCY IS BASED ON VISUAL
    BE REVIEWED MANOJ/ BASED
    SANJAY

    100% CHOCK TEST TO BE DONE WITH PROD


    CHOCK SKIPPING OF CHOCKED PCS WATER ANOTHER SIDE & MUST BE SUP 100% CHOCK TEST IS IMPLEMENTED
    IMPROPER TESTING GAS FLOW STOP 10 YC 4 NO CHOCK TEST IS PERFORMED 4 160 10 3 3 90
    TESTING & MIXED UP WITH OK PCS CONTROLLED BY CODING/MARKING ON SUDESH/ WITH MARKING
    EACH PART TEJPAL

    IMPROPER
    IMPROPER AIR MOISTURE PRESENT IN THE PRESSURE GUAGE & AIR BLOWING TIME
    WATER DRYING FUNCTIONNING OF 7 3 2 42 NOT REQUIRED NA NA
    BLOWING TUBE PERIOD MAINTAINED
    COMPRESSOR
    MOISTURE PRESENT IN THE DAILY MONITORING PROCESS CHECK
    RUSTING OF TUBES 5 3 2 30 NOT REQUIRED NA NA
    TUBE SHEET HAS BEN IMPLEMENTED.
    IMPROPER PERIODICALLY TRAINING PROVIDED TO ONLY TRAINED OPERATOR MUST
    FINAL FITMENT FITMENT PROBLEM 8 NEGLEGANCY OF OPERATOR 3 3 72 NA NA
    CHECKING/FITMENT OPERATOR. PERFORM THIS PROCESS
    WEAR & TEAR OF FITMENT PERIODICALLY JIG VERIFICATION IS
    3 2 48 NOT REQUIRED NA NA
    ZIG IMPLEMENTED
    PACKING STANDARD IS DISPLAYED AND
    PACKING/ IMPROPER SHORTAGE/EXCESS PACKING NOT DONE AS PER
    10 YC 3 PERIODICALLY BRAINSTORMING IS 2 60 NOT REQUIRED NA NA
    DISPATCH PACKING/DISPATCH OF MATERIAL STANDARD
    IMPARTED

    PACKING STANDARD IS DISPLAYED AND


    WRONG PACKING DONE DUE
    FITMENT PROBLEM 10 YC 4 PERIODICALLY BRAINSTORMING IS 2 80 NOT REQUIRED NA NA
    TO NEGLEGANCY OF OPT
    IMPARTED

    PERIODICALLY BRAINSTORMING OF
    NEGLENGACY OF PACKING
    MIXING PROBLEM 10 YC 4 OPERATORS & REVERIFICATION BY QC 2 80 NOT REQUIRED NA NA
    OPERATOR
    SUP BEFORE DISPATCH

    NO ACTION RECOMMENDED IF RPN<100


    ACTION RECOMMENDED IF RPN>=150
    IMMEDIATE ACTION IF RPN>150
    RECOMMENDED

    Page 33 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/25-11-14

    Part name-Plate finned coil inlet pipe assy Part Code-3P379454-1

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    Prepared By: Checked By: Approved BY:

    Page 34 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 00/26-02-15

    Part Name.:- Capillary tube assy Part Code:-3P393448-1

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    LENGTH
    FITMENT PROBLEM 10 YC IMPROPER SETTING OF M/C 4 M/C SET UP BY LINE SUPERVISOR 1 40 NOT REQUIRED NA NA
    SHORT/EXCESS
    IMPROPER SETTING OF FIRST OF SAMPLE CHECK SHEET IS
    3 1 30 NOT REQUIRED NA NA
    GUIDE ROLLER IMPLEMENTED.
    CUTTING
    APPERANCE NG
    FIRST OF SAMPLE CHECK SHEET AND
    VISUAL DEFFECT DENTS/SCRATCHES/ 5 YS DEFECTS IN CUTTING M/C DIE 4 2 40 NOT REQUIRED NA NA
    VISUAL INSPECTION IS IMPLEMENTED
    PINCHES
    WEAR & TEAR OF DIE 3 TOOL HISTORY CARD IMPLEMENTED 2 30 NOT REQUIRED NA NA
    EXTERNAL PARTICLES
    IMPROPER CLEANING FIRST OF SAMPLE CHECK SHEET IS
    DEBURRING BRAZING PROBLEM 4 OIL/COPPER CHIPS /GREASE 4 2 32 NOT REQUIRED NA NA
    OF TUBE ENDS IMPLEMENTED
    OUTSIDE THE TUBE.

    FULL/PARTIALLY EXTERNAL PARTICLES


    FIRST OF SAMPLE CHECK SHEET IS
    CHOCKING 5 OIL/COPPER CHIPS /GREASE 3 2 30 NOT REQUIRED NA NA
    IMPLEMENTED
    PROBLEM INSIDE THE TUBE.

    FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    FORMING DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED NA NA
    PARTS IMPARTED
    WEAR & TEAR OF TOOLS 5 TOOL HISTORY CARD IS IMPLEMENTED 2 100 NOT REQUIRED NA NA
    PRESSURE GAUGE DEPLOYED AND
    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED NA NA
    IMPLEMENTED

    FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    BIDDING DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED NA NA
    PARTS IMPARTED

    PRESSURE GAUGE DEPLOYED AND


    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED NA NA
    IMPLEMENTED
    IMPROPER IMPROPER SETTING OF MC & M/C SET UP BY CNC TRAINED OPERATOR
    FITMENT PROBLEM 10 YC 3 2 60 NOT REQUIRED NA NA
    DIMENSIONING FIXTURE & VERIFIED BY PROD SUP

    SPECIFIED MANDREL NOT TRAINING IS IMPARTED & FIRST OF


    3 1 30 NOT REQUIRED NA NA
    MANUAL / USED SAMPLE CHECK SHEET IS IMPLEMENTED
    CNC BENDING
    PROPERLY PLACING OF BENDED PART
    APPERANCE NG
    DENTS/ SCRATCHES/ IMPROPER HANDLING/ INTO TROLLY AS PER STANDARD / FIRST
    DENTS/SCRATCHES/ 5 YS 4 4 80 NOT REQUIRED NA NA
    PINCH DEFECTS IN DIE OFF SAMPLE CHECK SHEET IS
    PINCHES
    IMPLEMENTED

    EXTERNAL PARTICLES TCE SOLUTION CHANGE FREQUENCY IS


    T.C.E.
    IMPROPER CLEANING BRAZING PROBLEM 6 OIL/COPPER CHIPS /GREASE 2 DEFINED AS PER NO.OF PIECES WASHED 2 24 NOT REQUIRED NA NA
    CLEANING
    OUTSIDE THE TUBE. & MONITORING SHEET IS MPLEMENTED

    FULL/PARTIALLY EXTERNAL PARTICLES


    TCE SOLUTION CHANGE FREQUENCY IS
    CHOCKING 6 OIL/COPPER CHIPS /GREASE 2 2 24 NOT REQUIRED NA NA
    DEFINED AS PER NO.OF PIECES WASHED.
    PROBLEM INSIDE THE TUBE.

    IMPROPER COPPER CHIPS/EXTERNAL


    CHOCKING BLOWING PRESSURE STD (5-6 KG/CM2) &
    N2 BLOWING /INSUFFICIENT N2 7 PARTICLES REMAIN INSIDE 3 2 42 NOT REQUIRED NA NA
    PROBLEM TIME (5-10 SEC/PCS ) HAS BEEN SET UP
    FLUSHING TUBE

    MOISTURE PRESENT IN THE BLOWING PRESSURE STD (5-6 KG/CM2) &


    FUCTIONING NOT OK 7 3 2 42 NOT REQUIRED NA NA
    TUBE TIME (5-10 SEC/PCS ) HAS BEEN SET UP

    PROD
    FIXTURE VERIFICATION wrt FINAL
    IMPROPER ALL FIXTURE HAS BEEN MARKED & COLOR SUP FIXTURE VERIFICATION & FIRST OFF
    BRAZING FITMENT PROBLEM 10 YC BRAZING FIXTURE NOT OK 4 4 160 FITMENT JIG TO BE IMPLEMENTED 10 3 3 90
    DIMENSIONING CODED SUDESH/ SAMPLE SHEET IMPLEMENTED
    BEFORE STARTING THE PRODN
    TEJPAL

    ONLY TRAINED OPERATOR TO BE


    PROD ONLY CERTIFIED BRAZER IS ALLOWED
    ONLY SKILLED & SEMISKILLED ALLOWED TO BRAZE & PERIODICALLY
    IMPROPER BRAZING SUP TO BRAZE & BRAZER TRAINING HAS
    LEAKAGE/CHOCKING 10 YC UNTRAINED OPERATOR 4 OPERATORS ARE PERFORMING BRAZING 4 160 TRAINING SYSTEM TO BE 10 3 3 90
    LESS/EXCESS SUDESH/ BEEN IMPARTED TO SEMI SKILLED
    OPERATION. IMPLEMENTED TO SEMI SKILLED OPT
    TEJPAL BRAZER
    TO MAKE THEM TRAINED

    QC
    RED BIN LOCATION MUST BE UNDER RED BIN LOCATION IS DEFINED, ITS
    ENGG/
    SKIPPING OF LEAK PCS & TABLE & LEAKE PORTION TO BE RED USAGE TRAINING HAS BEEN IMPARTED
    LEAK TESTING IMPROPER TESTING GAS LEAKAGE 10 YC 4 RED BIN SYSTEM IS IMPLEMENTED 3 120 SUP 10 3 3 90
    MIXED UP WITH OK PCS MARKED & TRAINING HOW TO USE RED & RED MARKING AT THE LEAK
    MANOJ/
    BIN TO BE IMPARTED PORTION IS IMPLEMENTED
    SANJAY

    STRICTLY RECOMMENDED HIGHLY


    TRAINED OPERATOR TO PERFORM ONLY CERTIFIED LEAKAGE TESTING
    QC
    THIS OPERATION AND PERIODICALLY OPERATOR IS ALLOWED TO TEST &
    ENGG/
    IMPROPER PRESSURE & TRAINING TO THEM & SEMI-SKILLED PERIODICALLY TRAINING IS IMPARTED.
    5 TRAINED OPERATOR APPOINTED 4 200 SUP 10 3 3 90
    TESTING TIME OPERATOR MUST BE IMPARTED & AIR PRESSURE GUAGE IS LOCATED AT
    MANOJ/
    PRESSURE GAUGE MUST BE LOCATED EACH STATION AND MONITORING
    SANJAY
    ON EACH STATION & MONITORING SHEET IS IMPLEMENTED
    MUST BE DONE

    QC
    MINERAL OR RO-WATER TO BE USED ENGG/ RO WATER IS IMPLEMENTED &
    DIRECT TAP WATER IS USED & CHANGE
    CONDITION OF WATER 4 4 160 AND WATER CHANGE FREQUENCY TO SUP CHANGE FREQUENCY IS VISUAL 10 3 3 90
    FREQUENCY IS BASED ON VISUAL
    BE REVIEWED MANOJ/ BASED
    SANJAY

    100% CHOCK TEST TO BE DONE WITH PROD


    CHOCK SKIPPING OF CHOCKED PCS WATER ANOTHER SIDE & MUST BE SUP 100% CHOCK TEST IS IMPLEMENTED
    IMPROPER TESTING GAS FLOW STOP 10 YC 4 NO CHOCK TEST IS PERFORMED 4 160 10 3 3 90
    TESTING & MIXED UP WITH OK PCS CONTROLLED BY CODING/MARKING ON SUDESH/ WITH MARKING
    EACH PART TEJPAL

    IMPROPER
    IMPROPER AIR MOISTURE PRESENT IN THE PRESSURE GUAGE & AIR BLOWING TIME
    WATER DRYING FUNCTIONNING OF 7 3 2 42 NOT REQUIRED NA NA
    BLOWING TUBE PERIOD MAINTAINED
    COMPRESSOR
    MOISTURE PRESENT IN THE DAILY MONITORING PROCESS CHECK
    RUSTING OF TUBES 5 3 2 30 NOT REQUIRED NA NA
    TUBE SHEET HAS BEN IMPLEMENTED.
    IMPROPER PERIODICALLY TRAINING PROVIDED TO ONLY TRAINED OPERATOR MUST
    FINAL FITMENT FITMENT PROBLEM 8 NEGLEGANCY OF OPERATOR 3 3 72 NA NA
    CHECKING/FITMENT OPERATOR. PERFORM THIS PROCESS
    WEAR & TEAR OF FITMENT PERIODICALLY JIG VERIFICATION IS
    3 2 48 NOT REQUIRED NA NA
    ZIG IMPLEMENTED
    PACKING STANDARD IS DISPLAYED AND
    PACKING/ IMPROPER SHORTAGE/EXCESS PACKING NOT DONE AS PER
    10 YC 3 PERIODICALLY BRAINSTORMING IS 2 60 NOT REQUIRED NA NA
    DISPATCH PACKING/DISPATCH OF MATERIAL STANDARD
    IMPARTED
    PACKING STANDARD IS DISPLAYED AND
    WRONG PACKING DONE DUE
    FITMENT PROBLEM 10 YC 4 PERIODICALLY BRAINSTORMING IS 2 80 NOT REQUIRED NA NA
    TO NEGLEGANCY OF OPT
    IMPARTED

    Page 35 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 00/26-02-15

    Part Name.:- Capillary tube assy Part Code:-3P393448-1

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    PERIODICALLY BRAINSTORMING OF
    NEGLENGACY OF PACKING
    MIXING PROBLEM 10 YC 4 OPERATORS & REVERIFICATION BY QC 2 80 NOT REQUIRED NA NA
    OPERATOR
    SUP BEFORE DISPATCH

    NO ACTION RECOMMENDED IF RPN<100


    ACTION RECOMMENDED IF RPN>=150
    IMMEDIATE ACTION IF RPN>150
    RECOMMENDED
    Prepared By: Checked By: Approved BY:

    Page 36 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/20-04-15

    Part Name.:- Capillary tube assy Part Code:-3P401105-1

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    LENGTH
    FITMENT PROBLEM 10 YC IMPROPER SETTING OF M/C 4 M/C SET UP BY LINE SUPERVISOR 1 40 NOT REQUIRED NA NA
    SHORT/EXCESS
    IMPROPER SETTING OF FIRST OF SAMPLE CHECK SHEET IS
    3 1 30 NOT REQUIRED NA NA
    GUIDE ROLLER IMPLEMENTED.
    CUTTING
    APPERANCE NG
    FIRST OF SAMPLE CHECK SHEET AND
    VISUAL DEFFECT DENTS/SCRATCHES/ 5 YS DEFECTS IN CUTTING M/C DIE 4 2 40 NOT REQUIRED NA NA
    VISUAL INSPECTION IS IMPLEMENTED
    PINCHES
    WEAR & TEAR OF DIE 3 TOOL HISTORY CARD IMPLEMENTED 2 30 NOT REQUIRED NA NA
    EXTERNAL PARTICLES
    IMPROPER CLEANING FIRST OF SAMPLE CHECK SHEET IS
    DEBURRING BRAZING PROBLEM 4 OIL/COPPER CHIPS /GREASE 4 2 32 NOT REQUIRED NA NA
    OF TUBE ENDS IMPLEMENTED
    OUTSIDE THE TUBE.

    FULL/PARTIALLY EXTERNAL PARTICLES


    FIRST OF SAMPLE CHECK SHEET IS
    CHOCKING 5 OIL/COPPER CHIPS /GREASE 3 2 30 NOT REQUIRED NA NA
    IMPLEMENTED
    PROBLEM INSIDE THE TUBE.

    FORMING FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    EXPANDING DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED NA NA
    REDUCING PARTS IMPARTED

    WEAR & TEAR OF TOOLS 5 TOOL HISTORY CARD IS IMPLEMENTED 2 100 NOT REQUIRED NA NA
    PRESSURE GAUGE DEPLOYED AND
    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED NA NA
    IMPLEMENTED

    FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    BEADING DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED NA NA
    PARTS IMPARTED

    PRESSURE GAUGE DEPLOYED AND


    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED NA NA
    IMPLEMENTED
    IMPROPER IMPROPER SETTING OF MC & M/C SET UP BY CNC TRAINED OPERATOR
    FITMENT PROBLEM 10 YC 3 2 60 NOT REQUIRED NA NA
    DIMENSIONING FIXTURE & VERIFIED BY PROD SUP

    SPECIFIED MANDREL NOT TRAINING IS IMPARTED & FIRST OF


    3 1 30 NOT REQUIRED NA NA
    MANUAL / USED SAMPLE CHECK SHEET IS IMPLEMENTED
    CNC BENDING
    PROPERLY PLACING OF BENDED PART
    APPERANCE NG
    DENTS/ SCRATCHES/ IMPROPER HANDLING/ INTO TROLLY AS PER STANDARD / FIRST
    DENTS/SCRATCHES/ 5 YS 4 4 80 NOT REQUIRED NA NA
    PINCH DEFECTS IN DIE OFF SAMPLE CHECK SHEET IS
    PINCHES
    IMPLEMENTED

    EXTERNAL PARTICLES TCE SOLUTION CHANGE FREQUENCY IS


    T.C.E.
    IMPROPER CLEANING BRAZING PROBLEM 6 OIL/COPPER CHIPS /GREASE 2 DEFINED AS PER NO.OF PIECES WASHED 2 24 NOT REQUIRED NA NA
    CLEANING
    OUTSIDE THE TUBE. & MONITORING SHEET IS MPLEMENTED

    FULL/PARTIALLY EXTERNAL PARTICLES


    TCE SOLUTION CHANGE FREQUENCY IS
    CHOCKING 6 OIL/COPPER CHIPS /GREASE 2 2 24 NOT REQUIRED NA NA
    DEFINED AS PER NO.OF PIECES WASHED.
    PROBLEM INSIDE THE TUBE.

    PROD
    FIXTURE VERIFICATION wrt FINAL
    IMPROPER ALL FIXTURE HAS BEEN MARKED & COLOR SUP FIXTURE VERIFICATION & FIRST OFF
    BRAZING FITMENT PROBLEM 10 YC BRAZING FIXTURE NOT OK 4 4 160 FITMENT JIG TO BE IMPLEMENTED 10 3 3 90
    DIMENSIONING CODED SUDESH/ SAMPLE SHEET IMPLEMENTED
    BEFORE STARTING THE PRODN
    TEJPAL

    ONLY TRAINED OPERATOR TO BE


    PROD ONLY CERTIFIED BRAZER IS ALLOWED
    ONLY SKILLED & SEMISKILLED ALLOWED TO BRAZE & PERIODICALLY
    IMPROPER BRAZING SUP TO BRAZE & BRAZER TRAINING HAS
    LEAKAGE/CHOCKING 10 YC UNTRAINED OPERATOR 4 OPERATORS ARE PERFORMING BRAZING 4 160 TRAINING SYSTEM TO BE 10 3 3 90
    LESS/EXCESS SUDESH/ BEEN IMPARTED TO SEMI SKILLED
    OPERATION. IMPLEMENTED TO SEMI SKILLED OPT
    TEJPAL BRAZER
    TO MAKE THEM TRAINED

    QC
    RED BIN LOCATION MUST BE UNDER RED BIN LOCATION IS DEFINED, ITS
    ENGG/
    SKIPPING OF LEAK PCS & TABLE & LEAKE PORTION TO BE RED USAGE TRAINING HAS BEEN IMPARTED
    LEAK TESTING IMPROPER TESTING GAS LEAKAGE 10 YC 4 RED BIN SYSTEM IS IMPLEMENTED 3 120 SUP 10 3 3 90
    MIXED UP WITH OK PCS MARKED & TRAINING HOW TO USE RED & RED MARKING AT THE LEAK
    MANOJ/
    BIN TO BE IMPARTED PORTION IS IMPLEMENTED
    SANJAY

    STRICTLY RECOMMENDED HIGHLY


    TRAINED OPERATOR TO PERFORM ONLY CERTIFIED LEAKAGE TESTING
    QC
    THIS OPERATION AND PERIODICALLY OPERATOR IS ALLOWED TO TEST &
    ENGG/
    IMPROPER PRESSURE & TRAINING TO THEM & SEMI-SKILLED PERIODICALLY TRAINING IS IMPARTED.
    5 TRAINED OPERATOR APPOINTED 4 200 SUP 10 3 3 90
    TESTING TIME OPERATOR MUST BE IMPARTED & AIR PRESSURE GUAGE IS LOCATED AT
    MANOJ/
    PRESSURE GAUGE MUST BE LOCATED EACH STATION AND MONITORING
    SANJAY
    ON EACH STATION & MONITORING SHEET IS IMPLEMENTED
    MUST BE DONE

    QC
    MINERAL OR RO-WATER TO BE USED ENGG/ RO WATER IS IMPLEMENTED &
    DIRECT TAP WATER IS USED & CHANGE
    CONDITION OF WATER 4 4 160 AND WATER CHANGE FREQUENCY TO SUP CHANGE FREQUENCY IS VISUAL 10 3 3 90
    FREQUENCY IS BASED ON VISUAL
    BE REVIEWED MANOJ/ BASED
    SANJAY

    100% CHOCK TEST TO BE DONE WITH PROD


    CHOCK SKIPPING OF CHOCKED PCS WATER ANOTHER SIDE & MUST BE SUP 100% CHOCK TEST IS IMPLEMENTED
    IMPROPER TESTING GAS FLOW STOP 10 YC 4 NO CHOCK TEST IS PERFORMED 4 160 10 3 3 90
    TESTING & MIXED UP WITH OK PCS CONTROLLED BY CODING/MARKING ON SUDESH/ WITH MARKING
    EACH PART TEJPAL

    IMPROPER
    IMPROPER AIR MOISTURE PRESENT IN THE PRESSURE GUAGE & AIR BLOWING TIME
    WATER DRYING FUNCTIONNING OF 7 3 2 42 NOT REQUIRED NA NA
    BLOWING TUBE PERIOD MAINTAINED
    COMPRESSOR
    MOISTURE PRESENT IN THE DAILY MONITORING PROCESS CHECK
    RUSTING OF TUBES 5 3 2 30 NOT REQUIRED NA NA
    TUBE SHEET HAS BEN IMPLEMENTED.
    IMPROPER PERIODICALLY TRAINING PROVIDED TO ONLY TRAINED OPERATOR MUST
    FINAL FITMENT FITMENT PROBLEM 8 NEGLEGANCY OF OPERATOR 3 3 72 NA NA
    CHECKING/FITMENT OPERATOR. PERFORM THIS PROCESS
    WEAR & TEAR OF FITMENT PERIODICALLY JIG VERIFICATION IS
    3 2 48 NOT REQUIRED NA NA
    ZIG IMPLEMENTED
    IMPROPER COPPER CHIPS/EXTERNAL
    CHOCKING BLOWING PRESSURE STD (5-6 KG/CM2) &
    N2 BLOWING /INSUFFICIENT N2 7 PARTICLES REMAIN INSIDE 3 2 42 NOT REQUIRED NA NA
    PROBLEM TIME (5-10 SEC/PCS ) HAS BEEN SET UP
    FLUSHING TUBE

    MOISTURE PRESENT IN THE BLOWING PRESSURE STD (5-6 KG/CM2) &


    FUCTIONING NOT OK 7 3 2 42 NOT REQUIRED NA NA
    TUBE TIME (5-10 SEC/PCS ) HAS BEEN SET UP

    PACKING STANDARD IS DISPLAYED AND


    PACKING/ IMPROPER SHORTAGE/EXCESS PACKING NOT DONE AS PER
    10 YC 3 PERIODICALLY BRAINSTORMING IS 2 60 NOT REQUIRED NA NA
    DISPATCH PACKING/DISPATCH OF MATERIAL STANDARD
    IMPARTED

    Page 37 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/20-04-15

    Part Name.:- Capillary tube assy Part Code:-3P401105-1

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    PACKING STANDARD IS DISPLAYED AND
    WRONG PACKING DONE DUE
    FITMENT PROBLEM 10 YC 4 PERIODICALLY BRAINSTORMING IS 2 80 NOT REQUIRED NA NA
    TO NEGLEGANCY OF OPT
    IMPARTED

    PERIODICALLY BRAINSTORMING OF
    NEGLENGACY OF PACKING
    MIXING PROBLEM 10 YC 4 OPERATORS & REVERIFICATION BY QC 2 80 NOT REQUIRED NA NA
    OPERATOR
    SUP BEFORE DISPATCH

    NO ACTION RECOMMENDED IF RPN<100


    ACTION RECOMMENDED IF RPN>=150
    IMMEDIATE ACTION IF RPN>150
    RECOMMENDED
    Prepared By: Checked By: Approved BY:

    Page 38 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/07-05-15

    Part Name.:- Motor operated valve assy Part Code:-3P385436-1

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    LENGTH
    FITMENT PROBLEM 10 YC IMPROPER SETTING OF M/C 4 M/C SET UP BY LINE SUPERVISOR 1 40 NOT REQUIRED NA NA
    SHORT/EXCESS
    IMPROPER SETTING OF FIRST OF SAMPLE CHECK SHEET IS
    3 1 30 NOT REQUIRED NA NA
    GUIDE ROLLER IMPLEMENTED.
    CUTTING
    APPERANCE NG
    FIRST OF SAMPLE CHECK SHEET AND
    VISUAL DEFFECT DENTS/SCRATCHES/ 5 YS DEFECTS IN CUTTING M/C DIE 4 3 60 NOT REQUIRED NA NA
    VISUAL INSPECTION IS IMPLEMENTED
    PINCHES
    WEAR & TEAR OF DIE 3 TOOL HISTORY CARD IMPLEMENTED 2 30 NOT REQUIRED NA NA
    EXTERNAL PARTICLES
    IMPROPER CLEANING FIRST OF SAMPLE CHECK SHEET IS
    DEBURRING BRAZING PROBLEM 4 OIL/COPPER CHIPS /GREASE 4 2 32 NOT REQUIRED NA NA
    OF TUBE ENDS IMPLEMENTED
    OUTSIDE THE TUBE.

    FULL/PARTIALLY EXTERNAL PARTICLES


    FIRST OF SAMPLE CHECK SHEET IS
    CHOCKING 5 OIL/COPPER CHIPS /GREASE 3 2 30 NOT REQUIRED NA NA
    IMPLEMENTED
    PROBLEM INSIDE THE TUBE.

    FORMING FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    EXPANDING DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 4 /COLOR CODED; WI & TRAINING IS 3 120 NOT REQUIRED NA NA
    REDUCING PARTS IMPARTED

    WEAR & TEAR OF TOOLS 5 TOOL HISTORY CARD IS IMPLEMENTED 3 150 NOT REQUIRED NA NA
    PRESSURE GAUGE DEPLOYED AND
    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 3 150 NOT REQUIRED NA NA
    IMPLEMENTED
    IMPROPER IMPROPER SETTING OF MC & M/C SET UP BY CNC TRAINED OPERATOR
    FITMENT PROBLEM 10 YC 5 3 150 NOT REQUIRED NA NA
    DIMENSIONING FIXTURE & VERIFIED BY PROD SUP

    SPECIFIED MANDREL NOT TRAINING IS IMPARTED & FIRST OF


    5 3 150 NOT REQUIRED NA NA
    MANUAL / USED SAMPLE CHECK SHEET IS IMPLEMENTED
    CNC BENDING
    PROPERLY PLACING OF BENDED PART
    APPERANCE NG
    DENTS/ SCRATCHES/ IMPROPER HANDLING/ INTO TROLLY AS PER STANDARD / FIRST
    DENTS/SCRATCHES/ 5 YS 4 3 60 NOT REQUIRED NA NA
    PINCH DEFECTS IN DIE OFF SAMPLE CHECK SHEET IS
    PINCHES
    IMPLEMENTED

    EXTERNAL PARTICLES TCE SOLUTION CHANGE FREQUENCY IS


    T.C.E.
    IMPROPER CLEANING BRAZING PROBLEM 6 OIL/COPPER CHIPS /GREASE 3 DEFINED AS PER NO.OF PIECES WASHED 2 36 NOT REQUIRED NA NA
    CLEANING
    OUTSIDE THE TUBE. & MONITORING SHEET IS MPLEMENTED

    FULL/PARTIALLY EXTERNAL PARTICLES


    TCE SOLUTION CHANGE FREQUENCY IS
    CHOCKING 6 YS OIL/COPPER CHIPS /GREASE 5 4 120 NOT REQUIRED NA NA
    DEFINED AS PER NO.OF PIECES WASHED.
    PROBLEM INSIDE THE TUBE.

    PROD
    FIXTURE VERIFICATION wrt FINAL
    IMPROPER ALL FIXTURE HAS BEEN MARKED & COLOR SUP FIXTURE VERIFICATION & FIRST OFF
    BRAZING FITMENT PROBLEM 10 YC BRAZING FIXTURE NOT OK 5 3 150 FITMENT JIG TO BE IMPLEMENTED 10 3 3 90
    DIMENSIONING CODED SUDESH/ SAMPLE SHEET IMPLEMENTED
    BEFORE STARTING THE PRODN
    TEJPAL

    ONLY TRAINED OPERATOR TO BE


    PROD ONLY CERTIFIED BRAZER IS ALLOWED
    ONLY SKILLED & SEMISKILLED ALLOWED TO BRAZE & PERIODICALLY
    IMPROPER BRAZING SUP TO BRAZE & BRAZER TRAINING HAS
    LEAKAGE/CHOCKING 10 YC UNTRAINED OPERATOR 5 OPERATORS ARE PERFORMING BRAZING 3 150 TRAINING SYSTEM TO BE 10 3 3 90
    LESS/EXCESS SUDESH/ BEEN IMPARTED TO SEMI SKILLED
    OPERATION. IMPLEMENTED TO SEMI SKILLED OPT
    TEJPAL BRAZER
    TO MAKE THEM TRAINED

    QC
    RED BIN LOCATION MUST BE UNDER RED BIN LOCATION IS DEFINED, ITS
    ENGG/
    SKIPPING OF LEAK PCS & TABLE & LEAKE PORTION TO BE RED USAGE TRAINING HAS BEEN IMPARTED
    LEAK TESTING IMPROPER TESTING GAS LEAKAGE 10 YC 4 RED BIN SYSTEM IS IMPLEMENTED 2 80 SUP 10 3 3 90
    MIXED UP WITH OK PCS MARKED & TRAINING HOW TO USE RED & RED MARKING AT THE LEAK
    MANOJ/
    BIN TO BE IMPARTED PORTION IS IMPLEMENTED
    SANJAY

    STRICTLY RECOMMENDED HIGHLY


    TRAINED OPERATOR TO PERFORM ONLY CERTIFIED LEAKAGE TESTING
    QC
    THIS OPERATION AND PERIODICALLY OPERATOR IS ALLOWED TO TEST &
    ENGG/
    IMPROPER PRESSURE & TRAINING TO THEM & SEMI-SKILLED PERIODICALLY TRAINING IS IMPARTED.
    5 TRAINED OPERATOR APPOINTED 2 100 SUP 10 3 3 90
    TESTING TIME OPERATOR MUST BE IMPARTED & AIR PRESSURE GUAGE IS LOCATED AT
    MANOJ/
    PRESSURE GAUGE MUST BE LOCATED EACH STATION AND MONITORING
    SANJAY
    ON EACH STATION & MONITORING SHEET IS IMPLEMENTED
    MUST BE DONE

    QC
    MINERAL OR RO-WATER TO BE USED ENGG/ RO WATER IS IMPLEMENTED &
    DIRECT TAP WATER IS USED & CHANGE
    CONDITION OF WATER 4 2 80 AND WATER CHANGE FREQUENCY TO SUP CHANGE FREQUENCY IS VISUAL 10 3 3 90
    FREQUENCY IS BASED ON VISUAL
    BE REVIEWED MANOJ/ BASED
    SANJAY

    100% CHOCK TEST TO BE DONE WITH PROD


    CHOCK SKIPPING OF CHOCKED PCS WATER ANOTHER SIDE & MUST BE SUP 100% CHOCK TEST IS IMPLEMENTED
    IMPROPER TESTING GAS FLOW STOP 10 YC 4 NO CHOCK TEST IS PERFORMED 3 120 10 3 3 90
    TESTING & MIXED UP WITH OK PCS CONTROLLED BY CODING/MARKING ON SUDESH/ WITH MARKING
    EACH PART TEJPAL

    IMPROPER
    IMPROPER AIR MOISTURE PRESENT IN THE PRESSURE GUAGE & AIR BLOWING TIME
    WATER DRYING FUNCTIONNING OF 7 YS 5 3 105 NOT REQUIRED NA NA
    BLOWING TUBE PERIOD MAINTAINED
    COMPRESSOR
    MOISTURE PRESENT IN THE DAILY MONITORING PROCESS CHECK
    RUSTING OF TUBES 5 YS 5 3 75 NOT REQUIRED NA NA
    TUBE SHEET HAS BEN IMPLEMENTED.
    IMPROPER PERIODICALLY TRAINING PROVIDED TO ONLY TRAINED OPERATOR MUST
    FINAL FITMENT FITMENT PROBLEM 8 YS NEGLEGANCY OF OPERATOR 5 3 120 NA NA
    CHECKING/FITMENT OPERATOR. PERFORM THIS PROCESS
    WEAR & TEAR OF FITMENT PERIODICALLY JIG VERIFICATION IS
    3 2 48 NOT REQUIRED NA NA
    ZIG IMPLEMENTED
    IMPROPER COPPER CHIPS/EXTERNAL
    CHOCKING BLOWING PRESSURE STD (5-6 KG/CM2) &
    N2 BLOWING /INSUFFICIENT N2 7 PARTICLES REMAIN INSIDE 3 2 42 NOT REQUIRED NA NA
    PROBLEM TIME (5-10 SEC/PCS ) HAS BEEN SET UP
    FLUSHING TUBE

    MOISTURE PRESENT IN THE BLOWING PRESSURE STD (5-6 KG/CM2) &


    FUCTIONING NOT OK 7 YS 5 3 105 NOT REQUIRED NA NA
    TUBE TIME (5-10 SEC/PCS ) HAS BEEN SET UP

    PACKING STANDARD IS DISPLAYED AND


    PACKING/ IMPROPER SHORTAGE/EXCESS PACKING NOT DONE AS PER
    10 YC 5 PERIODICALLY BRAINSTORMING IS 3 150 NOT REQUIRED NA NA
    DISPATCH PACKING/DISPATCH OF MATERIAL STANDARD
    IMPARTED
    PACKING STANDARD IS DISPLAYED AND
    WRONG PACKING DONE DUE
    FITMENT PROBLEM 10 YC 4 PERIODICALLY BRAINSTORMING IS 3 120 NOT REQUIRED NA NA
    TO NEGLEGANCY OF OPT
    IMPARTED

    PERIODICALLY BRAINSTORMING OF
    NEGLENGACY OF PACKING
    MIXING PROBLEM 10 YC 4 OPERATORS & REVERIFICATION BY QC 3 120 NOT REQUIRED NA NA
    OPERATOR
    SUP BEFORE DISPATCH

    NO ACTION RECOMMENDED IF RPN<100

    Page 39 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/07-05-15

    Part Name.:- Motor operated valve assy Part Code:-3P385436-1

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    ACTION RECOMMENDED IF RPN>=150
    IMMEDIATE ACTION IF RPN>150
    RECOMMENDED
    Prepared By: Checked By: Approved BY:

    Page 40 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/07-05-15

    Part Name.:- Motor operated valve assy Part Code:-3P359138-2B

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    LENGTH
    FITMENT PROBLEM 10 YC IMPROPER SETTING OF M/C 4 M/C SET UP BY LINE SUPERVISOR 1 40 NOT REQUIRED NA NA
    SHORT/EXCESS
    IMPROPER SETTING OF FIRST OF SAMPLE CHECK SHEET IS
    3 1 30 NOT REQUIRED NA NA
    GUIDE ROLLER IMPLEMENTED.
    CUTTING
    APPERANCE NG
    FIRST OF SAMPLE CHECK SHEET AND
    VISUAL DEFFECT DENTS/SCRATCHES/ 5 YS DEFECTS IN CUTTING M/C DIE 4 3 60 NOT REQUIRED NA NA
    VISUAL INSPECTION IS IMPLEMENTED
    PINCHES
    WEAR & TEAR OF DIE 3 TOOL HISTORY CARD IMPLEMENTED 2 30 NOT REQUIRED NA NA
    EXTERNAL PARTICLES
    IMPROPER CLEANING FIRST OF SAMPLE CHECK SHEET IS
    DEBURRING BRAZING PROBLEM 4 OIL/COPPER CHIPS /GREASE 4 2 32 NOT REQUIRED NA NA
    OF TUBE ENDS IMPLEMENTED
    OUTSIDE THE TUBE.

    FULL/PARTIALLY EXTERNAL PARTICLES


    FIRST OF SAMPLE CHECK SHEET IS
    CHOCKING 5 OIL/COPPER CHIPS /GREASE 3 2 30 NOT REQUIRED NA NA
    IMPLEMENTED
    PROBLEM INSIDE THE TUBE.

    FORMING FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    EXPANDING DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 4 /COLOR CODED; WI & TRAINING IS 3 120 NOT REQUIRED NA NA
    REDUCING PARTS IMPARTED

    WEAR & TEAR OF TOOLS 5 TOOL HISTORY CARD IS IMPLEMENTED 3 150 NOT REQUIRED NA NA
    PRESSURE GAUGE DEPLOYED AND
    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 3 150 NOT REQUIRED NA NA
    IMPLEMENTED
    IMPROPER IMPROPER SETTING OF MC & M/C SET UP BY CNC TRAINED OPERATOR
    FITMENT PROBLEM 10 YC 5 3 150 NOT REQUIRED NA NA
    DIMENSIONING FIXTURE & VERIFIED BY PROD SUP

    SPECIFIED MANDREL NOT TRAINING IS IMPARTED & FIRST OF


    5 3 150 NOT REQUIRED NA NA
    MANUAL / USED SAMPLE CHECK SHEET IS IMPLEMENTED
    CNC BENDING
    PROPERLY PLACING OF BENDED PART
    APPERANCE NG
    DENTS/ SCRATCHES/ IMPROPER HANDLING/ INTO TROLLY AS PER STANDARD / FIRST
    DENTS/SCRATCHES/ 5 YS 4 3 60 NOT REQUIRED NA NA
    PINCH DEFECTS IN DIE OFF SAMPLE CHECK SHEET IS
    PINCHES
    IMPLEMENTED

    EXTERNAL PARTICLES TCE SOLUTION CHANGE FREQUENCY IS


    T.C.E.
    IMPROPER CLEANING BRAZING PROBLEM 6 OIL/COPPER CHIPS /GREASE 3 DEFINED AS PER NO.OF PIECES WASHED 2 36 NOT REQUIRED NA NA
    CLEANING
    OUTSIDE THE TUBE. & MONITORING SHEET IS MPLEMENTED

    FULL/PARTIALLY EXTERNAL PARTICLES


    TCE SOLUTION CHANGE FREQUENCY IS
    CHOCKING 6 YS OIL/COPPER CHIPS /GREASE 5 4 120 NOT REQUIRED NA NA
    DEFINED AS PER NO.OF PIECES WASHED.
    PROBLEM INSIDE THE TUBE.

    PROD
    FIXTURE VERIFICATION wrt FINAL
    IMPROPER ALL FIXTURE HAS BEEN MARKED & COLOR SUP FIXTURE VERIFICATION & FIRST OFF
    BRAZING FITMENT PROBLEM 10 YC BRAZING FIXTURE NOT OK 5 3 150 FITMENT JIG TO BE IMPLEMENTED 10 3 3 90
    DIMENSIONING CODED SUDESH/ SAMPLE SHEET IMPLEMENTED
    BEFORE STARTING THE PRODN
    TEJPAL

    ONLY TRAINED OPERATOR TO BE


    PROD ONLY CERTIFIED BRAZER IS ALLOWED
    ONLY SKILLED & SEMISKILLED ALLOWED TO BRAZE & PERIODICALLY
    IMPROPER BRAZING SUP TO BRAZE & BRAZER TRAINING HAS
    LEAKAGE/CHOCKING 10 YC UNTRAINED OPERATOR 5 OPERATORS ARE PERFORMING BRAZING 3 150 TRAINING SYSTEM TO BE 10 3 3 90
    LESS/EXCESS SUDESH/ BEEN IMPARTED TO SEMI SKILLED
    OPERATION. IMPLEMENTED TO SEMI SKILLED OPT
    TEJPAL BRAZER
    TO MAKE THEM TRAINED

    QC
    RED BIN LOCATION MUST BE UNDER RED BIN LOCATION IS DEFINED, ITS
    ENGG/
    SKIPPING OF LEAK PCS & TABLE & LEAKE PORTION TO BE RED USAGE TRAINING HAS BEEN IMPARTED
    LEAK TESTING IMPROPER TESTING GAS LEAKAGE 10 YC 4 RED BIN SYSTEM IS IMPLEMENTED 2 80 SUP 10 3 3 90
    MIXED UP WITH OK PCS MARKED & TRAINING HOW TO USE RED & RED MARKING AT THE LEAK
    MANOJ/
    BIN TO BE IMPARTED PORTION IS IMPLEMENTED
    SANJAY

    STRICTLY RECOMMENDED HIGHLY


    TRAINED OPERATOR TO PERFORM ONLY CERTIFIED LEAKAGE TESTING
    QC
    THIS OPERATION AND PERIODICALLY OPERATOR IS ALLOWED TO TEST &
    ENGG/
    IMPROPER PRESSURE & TRAINING TO THEM & SEMI-SKILLED PERIODICALLY TRAINING IS IMPARTED.
    5 TRAINED OPERATOR APPOINTED 2 100 SUP 10 3 3 90
    TESTING TIME OPERATOR MUST BE IMPARTED & AIR PRESSURE GUAGE IS LOCATED AT
    MANOJ/
    PRESSURE GAUGE MUST BE LOCATED EACH STATION AND MONITORING
    SANJAY
    ON EACH STATION & MONITORING SHEET IS IMPLEMENTED
    MUST BE DONE

    QC
    MINERAL OR RO-WATER TO BE USED ENGG/ RO WATER IS IMPLEMENTED &
    DIRECT TAP WATER IS USED & CHANGE
    CONDITION OF WATER 4 2 80 AND WATER CHANGE FREQUENCY TO SUP CHANGE FREQUENCY IS VISUAL 10 3 3 90
    FREQUENCY IS BASED ON VISUAL
    BE REVIEWED MANOJ/ BASED
    SANJAY

    100% CHOCK TEST TO BE DONE WITH PROD


    CHOCK SKIPPING OF CHOCKED PCS WATER ANOTHER SIDE & MUST BE SUP 100% CHOCK TEST IS IMPLEMENTED
    IMPROPER TESTING GAS FLOW STOP 10 YC 4 NO CHOCK TEST IS PERFORMED 3 120 10 3 3 90
    TESTING & MIXED UP WITH OK PCS CONTROLLED BY CODING/MARKING ON SUDESH/ WITH MARKING
    EACH PART TEJPAL

    IMPROPER
    IMPROPER AIR MOISTURE PRESENT IN THE PRESSURE GUAGE & AIR BLOWING TIME
    WATER DRYING FUNCTIONNING OF 7 YS 5 3 105 NOT REQUIRED NA NA
    BLOWING TUBE PERIOD MAINTAINED
    COMPRESSOR
    MOISTURE PRESENT IN THE DAILY MONITORING PROCESS CHECK
    RUSTING OF TUBES 5 YS 5 3 75 NOT REQUIRED NA NA
    TUBE SHEET HAS BEN IMPLEMENTED.
    IMPROPER PERIODICALLY TRAINING PROVIDED TO ONLY TRAINED OPERATOR MUST
    FINAL FITMENT FITMENT PROBLEM 8 YS NEGLEGANCY OF OPERATOR 5 3 120 NA NA
    CHECKING/FITMENT OPERATOR. PERFORM THIS PROCESS
    WEAR & TEAR OF FITMENT PERIODICALLY JIG VERIFICATION IS
    3 2 48 NOT REQUIRED NA NA
    ZIG IMPLEMENTED
    IMPROPER COPPER CHIPS/EXTERNAL
    CHOCKING BLOWING PRESSURE STD (5-6 KG/CM2) &
    N2 BLOWING /INSUFFICIENT N2 7 PARTICLES REMAIN INSIDE 3 2 42 NOT REQUIRED NA NA
    PROBLEM TIME (5-10 SEC/PCS ) HAS BEEN SET UP
    FLUSHING TUBE

    MOISTURE PRESENT IN THE BLOWING PRESSURE STD (5-6 KG/CM2) &


    FUCTIONING NOT OK 7 YS 5 3 105 NOT REQUIRED NA NA
    TUBE TIME (5-10 SEC/PCS ) HAS BEEN SET UP

    PACKING STANDARD IS DISPLAYED AND


    PACKING/ IMPROPER SHORTAGE/EXCESS PACKING NOT DONE AS PER
    10 YC 5 PERIODICALLY BRAINSTORMING IS 3 150 NOT REQUIRED NA NA
    DISPATCH PACKING/DISPATCH OF MATERIAL STANDARD
    IMPARTED
    PACKING STANDARD IS DISPLAYED AND
    WRONG PACKING DONE DUE
    FITMENT PROBLEM 10 YC 4 PERIODICALLY BRAINSTORMING IS 3 120 NOT REQUIRED NA NA
    TO NEGLEGANCY OF OPT
    IMPARTED

    PERIODICALLY BRAINSTORMING OF
    NEGLENGACY OF PACKING
    MIXING PROBLEM 10 YC 4 OPERATORS & REVERIFICATION BY QC 3 120 NOT REQUIRED NA NA
    OPERATOR
    SUP BEFORE DISPATCH

    NO ACTION RECOMMENDED IF RPN<100

    Page 41 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/07-05-15

    Part Name.:- Motor operated valve assy Part Code:-3P359138-2B

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    ACTION RECOMMENDED IF RPN>=150
    IMMEDIATE ACTION IF RPN>150
    RECOMMENDED
    Prepared By: Checked By: Approved BY:

    Page 42 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/06-06-15

    Part Name.:- Auxiliary inlet pipe assy Part Code:-2P401970-1A

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    LENGTH
    FITMENT PROBLEM 10 YC IMPROPER SETTING OF M/C 4 M/C SET UP BY LINE SUPERVISOR 1 40 NOT REQUIRED 10 3 3 90
    SHORT/EXCESS

    ONLY CERTIFIED CUTTING OPERATOR


    IMPROPER SETTING OF FIRST OF SAMPLE CHECK SHEET IS Cutting IS ALLOWED TO CUTTING TRAINING
    CUTTING 3 1 30 NOT REQUIRED
    GUIDE ROLLER IMPLEMENTED. Operator HAS BEEN IMPARTED TO SKILLED
    OPERATOR
    APPERANCE NG
    FIRST OF SAMPLE CHECK SHEET AND 10 3 3 90
    VISUAL DEFFECT DENTS/SCRATCHES/ 5 YS DEFECTS IN CUTTING M/C DIE 4 2 40 NOT REQUIRED
    VISUAL INSPECTION IS IMPLEMENTED
    PINCHES
    WEAR & TEAR OF DIE 3 TOOL HISTORY CARD IMPLEMENTED 2 30 NOT REQUIRED
    EXTERNAL PARTICLES
    IMPROPER CLEANING FIRST OF SAMPLE CHECK SHEET IS
    DEBURRING BRAZING PROBLEM 4 OIL/COPPER CHIPS /GREASE 4 2 32 NOT REQUIRED EDUCATION AND TRAINING PROVID TO 10 3 3 90
    OF TUBE ENDS IMPLEMENTED
    OUTSIDE THE TUBE. Deburring DEBURRING OPERATOR REMOVE
    FULL/PARTIALLY EXTERNAL PARTICLES Operator BURRS ALL COPPER AND CAPILLARY
    FIRST OF SAMPLE CHECK SHEET IS TUBE.
    CHOCKING 5 OIL/COPPER CHIPS /GREASE 3 2 30 NOT REQUIRED 10 3 3 90
    IMPLEMENTED
    PROBLEM INSIDE THE TUBE.

    FORMING FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    EXPANDING DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED
    REDUCING PARTS IMPARTED
    GAUGE VERIFICATION & FIRST OFF
    Forming
    SAMPLE SHEET IMPLEMENTED EVERY 10 3 3 90
    WEAR & TEAR OF TOOLS 5 TOOL HISTORY CARD IS IMPLEMENTED 2 100 NOT REQUIRED Operator
    PARTS
    PRESSURE GAUGE DEPLOYED AND
    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED
    IMPLEMENTED

    IMPROPER IMPROPER SETTING OF MC & M/C SET UP BY CNC TRAINED OPERATOR


    FITMENT PROBLEM 10 YC 3 2 60 NOT REQUIRED
    DIMENSIONING FIXTURE & VERIFIED BY PROD SUP

    Maual
    MANUAL / SPECIFIED MANDREL NOT TRAINING IS IMPARTED & FIRST OF bending JIG,FIXTURE VERIFICATION & FIRST
    3 1 30 NOT REQUIRED 10 3 3 90
    CNC BENDING USED SAMPLE CHECK SHEET IS IMPLEMENTED and CNC OFF SAMPLE SHEET IMPLEMENTED
    Operator

    PROPERLY PLACING OF BENDED PART


    APPERANCE NG
    DENTS/ SCRATCHES/ IMPROPER HANDLING/ INTO TROLLY AS PER STANDARD / FIRST
    DENTS/SCRATCHES/ 5 YS 4 4 80 NOT REQUIRED
    PINCH DEFECTS IN DIE OFF SAMPLE CHECK SHEET IS
    PINCHES
    IMPLEMENTED

    EXTERNAL PARTICLES TCE SOLUTION CHANGE FREQUENCY IS


    T.C.E.
    IMPROPER CLEANING BRAZING PROBLEM 6 OIL/COPPER CHIPS /GREASE 2 DEFINED AS PER NO.OF PIECES WASHED 2 24 NOT REQUIRED EDUCATION AND TRAINING PROVID TO
    CLEANING
    OUTSIDE THE TUBE. & MONITORING SHEET IS MPLEMENTED Quality TCE OPERATOR REMOVE
    10 3 3 90
    FULL/PARTIALLY EXTERNAL PARTICLES Inspector BURRS,DUST,OIL ALL COPPER AND
    TCE SOLUTION CHANGE FREQUENCY IS CAPILLARY TUBE.
    CHOCKING 6 OIL/COPPER CHIPS /GREASE 2 2 24 NOT REQUIRED
    DEFINED AS PER NO.OF PIECES WASHED.
    PROBLEM INSIDE THE TUBE.

    PROD
    FIXTURE VERIFICATION wrt FINAL
    IMPROPER ALL FIXTURE HAS BEEN MARKED & COLOR ENGG FIXTURE VERIFICATION & FIRST OFF
    BRAZING FITMENT PROBLEM 10 YC BRAZING FIXTURE NOT OK 4 4 160 FITMENT JIG TO BE IMPLEMENTED 10 3 3 90
    DIMENSIONING CODED SUNDARL SAMPLE SHEET IMPLEMENTED
    BEFORE STARTING THE PRODN
    AL

    ONLY TRAINED OPERATOR TO BE


    PROD ONLY CERTIFIED BRAZER IS ALLOWED
    ONLY SKILLED & SEMISKILLED ALLOWED TO BRAZE & PERIODICALLY
    IMPROPER BRAZING ENGG TO BRAZE & BRAZER TRAINING HAS
    LEAKAGE/CHOCKING 10 YC UNTRAINED OPERATOR 4 OPERATORS ARE PERFORMING BRAZING 4 160 TRAINING SYSTEM TO BE 10 3 3 90
    LESS/EXCESS SUNDARL BEEN IMPARTED TO SEMI SKILLED
    OPERATION. IMPLEMENTED TO SEMI SKILLED OPT
    AL BRAZER
    TO MAKE THEM TRAINED

    RED BIN LOCATION MUST BE UNDER RED BIN LOCATION IS DEFINED, ITS
    SKIPPING OF LEAK PCS & TABLE & LEAKE PORTION TO BE RED QC ENGG USAGE TRAINING HAS BEEN IMPARTED
    LEAK TESTING IMPROPER TESTING GAS LEAKAGE 10 YC 4 RED BIN SYSTEM IS IMPLEMENTED 3 120 10 3 3 90
    MIXED UP WITH OK PCS MARKED & TRAINING HOW TO USE RED VINOD & RED MARKING AT THE LEAK
    BIN TO BE IMPARTED PORTION IS IMPLEMENTED

    STRICTLY RECOMMENDED HIGHLY


    TRAINED OPERATOR TO PERFORM ONLY CERTIFIED LEAKAGE TESTING
    THIS OPERATION AND PERIODICALLY OPERATOR IS ALLOWED TO TEST &
    IMPROPER PRESSURE & TRAINING TO THEM & SEMI-SKILLED QC ENGG PERIODICALLY TRAINING IS IMPARTED.
    5 TRAINED OPERATOR APPOINTED 4 200 10 3 3 90
    TESTING TIME OPERATOR MUST BE IMPARTED & VINOD AIR PRESSURE GUAGE IS LOCATED AT
    PRESSURE GAUGE MUST BE LOCATED EACH STATION AND MONITORING
    ON EACH STATION & MONITORING SHEET IS IMPLEMENTED
    MUST BE DONE

    MINERAL OR RO-WATER TO BE USED RO WATER IS IMPLEMENTED &


    DIRECT TAP WATER IS USED & CHANGE QC ENGG
    CONDITION OF WATER 4 4 160 AND WATER CHANGE FREQUENCY TO CHANGE FREQUENCY IS VISUAL 10 3 3 90
    FREQUENCY IS BASED ON VISUAL DURGESH
    BE REVIEWED BASED

    100% CHOCK TEST TO BE DONE WITH PROD


    CHOCK SKIPPING OF CHOCKED PCS WATER ANOTHER SIDE & MUST BE ENGG 100% CHOCK TEST IS IMPLEMENTED
    IMPROPER TESTING GAS FLOW STOP 10 YC 4 NO CHOCK TEST IS PERFORMED 4 160 10 3 3 90
    TESTING & MIXED UP WITH OK PCS CONTROLLED BY CODING/MARKING ON SUNDARL WITH MARKING
    EACH PART AL

    IMPROPER
    IMPROPER AIR MOISTURE PRESENT IN THE PRESSURE GUAGE & AIR BLOWING TIME
    WATER DRYING FUNCTIONNING OF 7 3 2 42 NOT REQUIRED NA
    BLOWING TUBE PERIOD MAINTAINED
    COMPRESSOR Operator
    MOISTURE PRESENT IN THE DAILY MONITORING PROCESS CHECK
    RUSTING OF TUBES 5 3 2 30 NOT REQUIRED NA
    TUBE SHEET HAS BEN IMPLEMENTED.
    IMPROPER PERIODICALLY TRAINING PROVIDED TO ONLY TRAINED OPERATOR MUST
    FINAL FITMENT FITMENT PROBLEM 8 NEGLEGANCY OF OPERATOR 3 3 72
    CHECKING/FITMENT OPERATOR. PERFORM THIS PROCESS Quality
    ALL FINAL FITMENT JIG CALIBRATED 10 3 3 90
    WEAR & TEAR OF FITMENT PERIODICALLY JIG VERIFICATION IS Inspector
    3 2 48 NOT REQUIRED
    ZIG IMPLEMENTED
    IMPROPER COPPER CHIPS/EXTERNAL
    CHOCKING BLOWING PRESSURE STD (5-6 KG/CM2) &
    N2 BLOWING /INSUFFICIENT N2 7 PARTICLES REMAIN INSIDE 3 2 42 NOT REQUIRED NA
    PROBLEM TIME (5-10 SEC/PCS ) HAS BEEN SET UP
    FLUSHING TUBE
    Operator
    MOISTURE PRESENT IN THE BLOWING PRESSURE STD (5-6 KG/CM2) &
    FUCTIONING NOT OK 7 3 2 42 NOT REQUIRED NA
    TUBE TIME (5-10 SEC/PCS ) HAS BEEN SET UP

    PACKING STANDARD IS DISPLAYED AND


    PACKING/ IMPROPER SHORTAGE/EXCESS PACKING NOT DONE AS PER
    10 YC 3 PERIODICALLY BRAINSTORMING IS 2 60 NOT REQUIRED
    DISPATCH PACKING/DISPATCH OF MATERIAL STANDARD
    IMPARTED
    PACKING STANDARD IS DISPLAYED AND Packing
    WRONG PACKING DONE DUE 100% MANUAL COUNTING EACH PARTS
    FITMENT PROBLEM 10 YC 4 PERIODICALLY BRAINSTORMING IS 2 80 NOT REQUIRED Operator 10 3 3 90
    TO NEGLEGANCY OF OPT BEFORE DISPATCH
    IMPARTED and Officer
    PERIODICALLY BRAINSTORMING OF
    NEGLENGACY OF PACKING
    MIXING PROBLEM 10 YC 4 OPERATORS & REVERIFICATION BY QC 2 80 NOT REQUIRED
    OPERATOR
    SUP BEFORE DISPATCH

    Page 43 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/06-06-15

    Part Name.:- Auxiliary inlet pipe assy Part Code:-2P401970-1A

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    NO ACTION RECOMMENDED IF RPN<100
    ACTION RECOMMENDED IF RPN>=150
    IMMEDIATE ACTION IF RPN>150
    RECOMMENDED
    Prepared By: Checked By: Approved BY:

    Page 44 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/06-06-15

    Part Name.:- Auxiliary inlet pipe assy Part Code:-3P364512-1A

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    LENGTH
    FITMENT PROBLEM 10 YC IMPROPER SETTING OF M/C 4 M/C SET UP BY LINE SUPERVISOR 1 40 NOT REQUIRED 10 3 3 90
    SHORT/EXCESS

    ONLY CERTIFIED CUTTING OPERATOR


    IMPROPER SETTING OF FIRST OF SAMPLE CHECK SHEET IS Cutting IS ALLOWED TO CUTTING TRAINING
    CUTTING 3 1 30 NOT REQUIRED
    GUIDE ROLLER IMPLEMENTED. Operator HAS BEEN IMPARTED TO SKILLED
    OPERATOR
    APPERANCE NG
    FIRST OF SAMPLE CHECK SHEET AND 10 3 3 90
    VISUAL DEFFECT DENTS/SCRATCHES/ 5 YS DEFECTS IN CUTTING M/C DIE 4 2 40 NOT REQUIRED
    VISUAL INSPECTION IS IMPLEMENTED
    PINCHES
    WEAR & TEAR OF DIE 3 TOOL HISTORY CARD IMPLEMENTED 2 30 NOT REQUIRED
    EXTERNAL PARTICLES
    IMPROPER CLEANING FIRST OF SAMPLE CHECK SHEET IS
    DEBURRING BRAZING PROBLEM 4 OIL/COPPER CHIPS /GREASE 4 2 32 NOT REQUIRED EDUCATION AND TRAINING PROVID TO 10 3 3 90
    OF TUBE ENDS IMPLEMENTED
    OUTSIDE THE TUBE. Deburring DEBURRING OPERATOR REMOVE
    FULL/PARTIALLY EXTERNAL PARTICLES Operator BURRS ALL COPPER AND CAPILLARY
    FIRST OF SAMPLE CHECK SHEET IS TUBE.
    CHOCKING 5 OIL/COPPER CHIPS /GREASE 3 2 30 NOT REQUIRED 10 3 3 90
    IMPLEMENTED
    PROBLEM INSIDE THE TUBE.

    FORMING FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    EXPANDING DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED
    REDUCING PARTS IMPARTED
    GAUGE VERIFICATION & FIRST OFF
    Forming
    SAMPLE SHEET IMPLEMENTED EVERY 10 3 3 90
    WEAR & TEAR OF TOOLS 5 TOOL HISTORY CARD IS IMPLEMENTED 2 100 NOT REQUIRED Operator
    PARTS
    PRESSURE GAUGE DEPLOYED AND
    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED
    IMPLEMENTED

    IMPROPER IMPROPER SETTING OF MC & M/C SET UP BY CNC TRAINED OPERATOR


    FITMENT PROBLEM 10 YC 3 2 60 NOT REQUIRED
    DIMENSIONING FIXTURE & VERIFIED BY PROD SUP

    Maual
    MANUAL / SPECIFIED MANDREL NOT TRAINING IS IMPARTED & FIRST OF bending JIG,FIXTURE VERIFICATION & FIRST
    3 1 30 NOT REQUIRED 10 3 3 90
    CNC BENDING USED SAMPLE CHECK SHEET IS IMPLEMENTED and CNC OFF SAMPLE SHEET IMPLEMENTED
    Operator

    PROPERLY PLACING OF BENDED PART


    APPERANCE NG
    DENTS/ SCRATCHES/ IMPROPER HANDLING/ INTO TROLLY AS PER STANDARD / FIRST
    DENTS/SCRATCHES/ 5 YS 4 4 80 NOT REQUIRED
    PINCH DEFECTS IN DIE OFF SAMPLE CHECK SHEET IS
    PINCHES
    IMPLEMENTED

    EXTERNAL PARTICLES TCE SOLUTION CHANGE FREQUENCY IS


    T.C.E.
    IMPROPER CLEANING BRAZING PROBLEM 6 OIL/COPPER CHIPS /GREASE 2 DEFINED AS PER NO.OF PIECES WASHED 2 24 NOT REQUIRED EDUCATION AND TRAINING PROVID TO
    CLEANING
    OUTSIDE THE TUBE. & MONITORING SHEET IS MPLEMENTED Quality TCE OPERATOR REMOVE
    10 3 3 90
    FULL/PARTIALLY EXTERNAL PARTICLES Inspector BURRS,DUST,OIL ALL COPPER AND
    TCE SOLUTION CHANGE FREQUENCY IS CAPILLARY TUBE.
    CHOCKING 6 OIL/COPPER CHIPS /GREASE 2 2 24 NOT REQUIRED
    DEFINED AS PER NO.OF PIECES WASHED.
    PROBLEM INSIDE THE TUBE.

    PROD
    FIXTURE VERIFICATION wrt FINAL
    IMPROPER ALL FIXTURE HAS BEEN MARKED & COLOR ENGG FIXTURE VERIFICATION & FIRST OFF
    BRAZING FITMENT PROBLEM 10 YC BRAZING FIXTURE NOT OK 4 4 160 FITMENT JIG TO BE IMPLEMENTED 10 3 3 90
    DIMENSIONING CODED SUNDARL SAMPLE SHEET IMPLEMENTED
    BEFORE STARTING THE PRODN
    AL

    ONLY TRAINED OPERATOR TO BE


    PROD ONLY CERTIFIED BRAZER IS ALLOWED
    ONLY SKILLED & SEMISKILLED ALLOWED TO BRAZE & PERIODICALLY
    IMPROPER BRAZING ENGG TO BRAZE & BRAZER TRAINING HAS
    LEAKAGE/CHOCKING 10 YC UNTRAINED OPERATOR 4 OPERATORS ARE PERFORMING BRAZING 4 160 TRAINING SYSTEM TO BE 10 3 3 90
    LESS/EXCESS SUNDARL BEEN IMPARTED TO SEMI SKILLED
    OPERATION. IMPLEMENTED TO SEMI SKILLED OPT
    AL BRAZER
    TO MAKE THEM TRAINED

    RED BIN LOCATION MUST BE UNDER RED BIN LOCATION IS DEFINED, ITS
    SKIPPING OF LEAK PCS & TABLE & LEAKE PORTION TO BE RED QC ENGG USAGE TRAINING HAS BEEN IMPARTED
    LEAK TESTING IMPROPER TESTING GAS LEAKAGE 10 YC 4 RED BIN SYSTEM IS IMPLEMENTED 3 120 10 3 3 90
    MIXED UP WITH OK PCS MARKED & TRAINING HOW TO USE RED VINOD & RED MARKING AT THE LEAK
    BIN TO BE IMPARTED PORTION IS IMPLEMENTED

    STRICTLY RECOMMENDED HIGHLY


    TRAINED OPERATOR TO PERFORM ONLY CERTIFIED LEAKAGE TESTING
    THIS OPERATION AND PERIODICALLY OPERATOR IS ALLOWED TO TEST &
    IMPROPER PRESSURE & TRAINING TO THEM & SEMI-SKILLED QC ENGG PERIODICALLY TRAINING IS IMPARTED.
    5 TRAINED OPERATOR APPOINTED 4 200 10 3 3 90
    TESTING TIME OPERATOR MUST BE IMPARTED & VINOD AIR PRESSURE GUAGE IS LOCATED AT
    PRESSURE GAUGE MUST BE LOCATED EACH STATION AND MONITORING
    ON EACH STATION & MONITORING SHEET IS IMPLEMENTED
    MUST BE DONE

    MINERAL OR RO-WATER TO BE USED RO WATER IS IMPLEMENTED &


    DIRECT TAP WATER IS USED & CHANGE QC ENGG
    CONDITION OF WATER 4 4 160 AND WATER CHANGE FREQUENCY TO CHANGE FREQUENCY IS VISUAL 10 3 3 90
    FREQUENCY IS BASED ON VISUAL DURGESH
    BE REVIEWED BASED

    100% CHOCK TEST TO BE DONE WITH PROD


    CHOCK SKIPPING OF CHOCKED PCS WATER ANOTHER SIDE & MUST BE ENGG 100% CHOCK TEST IS IMPLEMENTED
    IMPROPER TESTING GAS FLOW STOP 10 YC 4 NO CHOCK TEST IS PERFORMED 4 160 10 3 3 90
    TESTING & MIXED UP WITH OK PCS CONTROLLED BY CODING/MARKING ON SUNDARL WITH MARKING
    EACH PART AL

    IMPROPER
    IMPROPER AIR MOISTURE PRESENT IN THE PRESSURE GUAGE & AIR BLOWING TIME
    WATER DRYING FUNCTIONNING OF 7 3 2 42 NOT REQUIRED NA
    BLOWING TUBE PERIOD MAINTAINED
    COMPRESSOR Operator
    MOISTURE PRESENT IN THE DAILY MONITORING PROCESS CHECK
    RUSTING OF TUBES 5 3 2 30 NOT REQUIRED NA
    TUBE SHEET HAS BEN IMPLEMENTED.
    IMPROPER PERIODICALLY TRAINING PROVIDED TO ONLY TRAINED OPERATOR MUST
    FINAL FITMENT FITMENT PROBLEM 8 NEGLEGANCY OF OPERATOR 3 3 72
    CHECKING/FITMENT OPERATOR. PERFORM THIS PROCESS Quality
    ALL FINAL FITMENT JIG CALIBRATED 10 3 3 90
    WEAR & TEAR OF FITMENT PERIODICALLY JIG VERIFICATION IS Inspector
    3 2 48 NOT REQUIRED
    ZIG IMPLEMENTED
    IMPROPER COPPER CHIPS/EXTERNAL
    CHOCKING BLOWING PRESSURE STD (5-6 KG/CM2) &
    N2 BLOWING /INSUFFICIENT N2 7 PARTICLES REMAIN INSIDE 3 2 42 NOT REQUIRED NA
    PROBLEM TIME (5-10 SEC/PCS ) HAS BEEN SET UP
    FLUSHING TUBE
    Operator
    MOISTURE PRESENT IN THE BLOWING PRESSURE STD (5-6 KG/CM2) &
    FUCTIONING NOT OK 7 3 2 42 NOT REQUIRED NA
    TUBE TIME (5-10 SEC/PCS ) HAS BEEN SET UP

    PACKING STANDARD IS DISPLAYED AND


    PACKING/ IMPROPER SHORTAGE/EXCESS PACKING NOT DONE AS PER
    10 YC 3 PERIODICALLY BRAINSTORMING IS 2 60 NOT REQUIRED
    DISPATCH PACKING/DISPATCH OF MATERIAL STANDARD
    IMPARTED
    PACKING STANDARD IS DISPLAYED AND Packing
    WRONG PACKING DONE DUE 100% MANUAL COUNTING EACH PARTS
    FITMENT PROBLEM 10 YC 4 PERIODICALLY BRAINSTORMING IS 2 80 NOT REQUIRED Operator 10 3 3 90
    TO NEGLEGANCY OF OPT BEFORE DISPATCH
    IMPARTED and Officer
    PERIODICALLY BRAINSTORMING OF
    NEGLENGACY OF PACKING
    MIXING PROBLEM 10 YC 4 OPERATORS & REVERIFICATION BY QC 2 80 NOT REQUIRED
    OPERATOR
    SUP BEFORE DISPATCH

    Page 45 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/06-06-15

    Part Name.:- Auxiliary inlet pipe assy Part Code:-3P364512-1A

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    NO ACTION RECOMMENDED IF RPN<100
    ACTION RECOMMENDED IF RPN>=150
    IMMEDIATE ACTION IF RPN>150
    RECOMMENDED
    Prepared By: Checked By: Approved BY:

    Page 46 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/06-06-15

    Part Name.:- Auxiliary Outlet pipe assy Part Code:-3P346162-1F

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    LENGTH
    FITMENT PROBLEM 10 YC IMPROPER SETTING OF M/C 4 M/C SET UP BY LINE SUPERVISOR 1 40 NOT REQUIRED 10 3 3 90
    SHORT/EXCESS

    ONLY CERTIFIED CUTTING OPERATOR


    IMPROPER SETTING OF FIRST OF SAMPLE CHECK SHEET IS Cutting IS ALLOWED TO CUTTING TRAINING
    CUTTING 3 1 30 NOT REQUIRED
    GUIDE ROLLER IMPLEMENTED. Operator HAS BEEN IMPARTED TO SKILLED
    OPERATOR
    APPERANCE NG
    FIRST OF SAMPLE CHECK SHEET AND 10 3 3 90
    VISUAL DEFFECT DENTS/SCRATCHES/ 5 YS DEFECTS IN CUTTING M/C DIE 4 2 40 NOT REQUIRED
    VISUAL INSPECTION IS IMPLEMENTED
    PINCHES
    WEAR & TEAR OF DIE 3 TOOL HISTORY CARD IMPLEMENTED 2 30 NOT REQUIRED
    EXTERNAL PARTICLES
    IMPROPER CLEANING FIRST OF SAMPLE CHECK SHEET IS
    DEBURRING BRAZING PROBLEM 4 OIL/COPPER CHIPS /GREASE 4 2 32 NOT REQUIRED EDUCATION AND TRAINING PROVID TO 10 3 3 90
    OF TUBE ENDS IMPLEMENTED
    OUTSIDE THE TUBE. Deburring DEBURRING OPERATOR REMOVE
    FULL/PARTIALLY EXTERNAL PARTICLES Operator BURRS ALL COPPER AND CAPILLARY
    FIRST OF SAMPLE CHECK SHEET IS TUBE.
    CHOCKING 5 OIL/COPPER CHIPS /GREASE 3 2 30 NOT REQUIRED 10 3 3 90
    IMPLEMENTED
    PROBLEM INSIDE THE TUBE.

    FORMING FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    EXPANDING DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED
    REDUCING PARTS IMPARTED
    GAUGE VERIFICATION & FIRST OFF
    Forming
    SAMPLE SHEET IMPLEMENTED EVERY 10 3 3 90
    WEAR & TEAR OF TOOLS 5 TOOL HISTORY CARD IS IMPLEMENTED 2 100 NOT REQUIRED Operator
    PARTS
    PRESSURE GAUGE DEPLOYED AND
    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED
    IMPLEMENTED

    IMPROPER IMPROPER SETTING OF MC & M/C SET UP BY CNC TRAINED OPERATOR


    FITMENT PROBLEM 10 YC 3 2 60 NOT REQUIRED
    DIMENSIONING FIXTURE & VERIFIED BY PROD SUP

    Maual
    MANUAL / SPECIFIED MANDREL NOT TRAINING IS IMPARTED & FIRST OF bending JIG,FIXTURE VERIFICATION & FIRST
    3 1 30 NOT REQUIRED 10 3 3 90
    CNC BENDING USED SAMPLE CHECK SHEET IS IMPLEMENTED and CNC OFF SAMPLE SHEET IMPLEMENTED
    Operator

    PROPERLY PLACING OF BENDED PART


    APPERANCE NG
    DENTS/ SCRATCHES/ IMPROPER HANDLING/ INTO TROLLY AS PER STANDARD / FIRST
    DENTS/SCRATCHES/ 5 YS 4 4 80 NOT REQUIRED
    PINCH DEFECTS IN DIE OFF SAMPLE CHECK SHEET IS
    PINCHES
    IMPLEMENTED

    EXTERNAL PARTICLES TCE SOLUTION CHANGE FREQUENCY IS


    T.C.E.
    IMPROPER CLEANING BRAZING PROBLEM 6 OIL/COPPER CHIPS /GREASE 2 DEFINED AS PER NO.OF PIECES WASHED 2 24 NOT REQUIRED EDUCATION AND TRAINING PROVID TO
    CLEANING
    OUTSIDE THE TUBE. & MONITORING SHEET IS MPLEMENTED Quality TCE OPERATOR REMOVE
    10 3 3 90
    FULL/PARTIALLY EXTERNAL PARTICLES Inspector BURRS,DUST,OIL ALL COPPER AND
    TCE SOLUTION CHANGE FREQUENCY IS CAPILLARY TUBE.
    CHOCKING 6 OIL/COPPER CHIPS /GREASE 2 2 24 NOT REQUIRED
    DEFINED AS PER NO.OF PIECES WASHED.
    PROBLEM INSIDE THE TUBE.

    PROD
    FIXTURE VERIFICATION wrt FINAL
    IMPROPER ALL FIXTURE HAS BEEN MARKED & COLOR ENGG FIXTURE VERIFICATION & FIRST OFF
    BRAZING FITMENT PROBLEM 10 YC BRAZING FIXTURE NOT OK 4 4 160 FITMENT JIG TO BE IMPLEMENTED 10 3 3 90
    DIMENSIONING CODED SUNDARL SAMPLE SHEET IMPLEMENTED
    BEFORE STARTING THE PRODN
    AL

    ONLY TRAINED OPERATOR TO BE


    PROD ONLY CERTIFIED BRAZER IS ALLOWED
    ONLY SKILLED & SEMISKILLED ALLOWED TO BRAZE & PERIODICALLY
    IMPROPER BRAZING ENGG TO BRAZE & BRAZER TRAINING HAS
    LEAKAGE/CHOCKING 10 YC UNTRAINED OPERATOR 4 OPERATORS ARE PERFORMING BRAZING 4 160 TRAINING SYSTEM TO BE 10 3 3 90
    LESS/EXCESS SUNDARL BEEN IMPARTED TO SEMI SKILLED
    OPERATION. IMPLEMENTED TO SEMI SKILLED OPT
    AL BRAZER
    TO MAKE THEM TRAINED

    RED BIN LOCATION MUST BE UNDER RED BIN LOCATION IS DEFINED, ITS
    SKIPPING OF LEAK PCS & TABLE & LEAKE PORTION TO BE RED QC ENGG USAGE TRAINING HAS BEEN IMPARTED
    LEAK TESTING IMPROPER TESTING GAS LEAKAGE 10 YC 4 RED BIN SYSTEM IS IMPLEMENTED 3 120 10 3 3 90
    MIXED UP WITH OK PCS MARKED & TRAINING HOW TO USE RED VINOD & RED MARKING AT THE LEAK
    BIN TO BE IMPARTED PORTION IS IMPLEMENTED

    STRICTLY RECOMMENDED HIGHLY


    TRAINED OPERATOR TO PERFORM ONLY CERTIFIED LEAKAGE TESTING
    THIS OPERATION AND PERIODICALLY OPERATOR IS ALLOWED TO TEST &
    IMPROPER PRESSURE & TRAINING TO THEM & SEMI-SKILLED QC ENGG PERIODICALLY TRAINING IS IMPARTED.
    5 TRAINED OPERATOR APPOINTED 4 200 10 3 3 90
    TESTING TIME OPERATOR MUST BE IMPARTED & VINOD AIR PRESSURE GUAGE IS LOCATED AT
    PRESSURE GAUGE MUST BE LOCATED EACH STATION AND MONITORING
    ON EACH STATION & MONITORING SHEET IS IMPLEMENTED
    MUST BE DONE

    MINERAL OR RO-WATER TO BE USED RO WATER IS IMPLEMENTED &


    DIRECT TAP WATER IS USED & CHANGE QC ENGG
    CONDITION OF WATER 4 4 160 AND WATER CHANGE FREQUENCY TO CHANGE FREQUENCY IS VISUAL 10 3 3 90
    FREQUENCY IS BASED ON VISUAL DURGESH
    BE REVIEWED BASED

    100% CHOCK TEST TO BE DONE WITH PROD


    CHOCK SKIPPING OF CHOCKED PCS WATER ANOTHER SIDE & MUST BE ENGG 100% CHOCK TEST IS IMPLEMENTED
    IMPROPER TESTING GAS FLOW STOP 10 YC 4 NO CHOCK TEST IS PERFORMED 4 160 10 3 3 90
    TESTING & MIXED UP WITH OK PCS CONTROLLED BY CODING/MARKING ON SUNDARL WITH MARKING
    EACH PART AL

    IMPROPER
    IMPROPER AIR MOISTURE PRESENT IN THE PRESSURE GUAGE & AIR BLOWING TIME
    WATER DRYING FUNCTIONNING OF 7 3 2 42 NOT REQUIRED NA
    BLOWING TUBE PERIOD MAINTAINED
    COMPRESSOR Operator
    MOISTURE PRESENT IN THE DAILY MONITORING PROCESS CHECK
    RUSTING OF TUBES 5 3 2 30 NOT REQUIRED NA
    TUBE SHEET HAS BEN IMPLEMENTED.
    IMPROPER PERIODICALLY TRAINING PROVIDED TO ONLY TRAINED OPERATOR MUST
    FINAL FITMENT FITMENT PROBLEM 8 NEGLEGANCY OF OPERATOR 3 3 72
    CHECKING/FITMENT OPERATOR. PERFORM THIS PROCESS Quality
    ALL FINAL FITMENT JIG CALIBRATED 10 3 3 90
    WEAR & TEAR OF FITMENT PERIODICALLY JIG VERIFICATION IS Inspector
    3 2 48 NOT REQUIRED
    ZIG IMPLEMENTED
    IMPROPER COPPER CHIPS/EXTERNAL
    CHOCKING BLOWING PRESSURE STD (5-6 KG/CM2) &
    N2 BLOWING /INSUFFICIENT N2 7 PARTICLES REMAIN INSIDE 3 2 42 NOT REQUIRED NA
    PROBLEM TIME (5-10 SEC/PCS ) HAS BEEN SET UP
    FLUSHING TUBE
    Operator
    MOISTURE PRESENT IN THE BLOWING PRESSURE STD (5-6 KG/CM2) &
    FUCTIONING NOT OK 7 3 2 42 NOT REQUIRED NA
    TUBE TIME (5-10 SEC/PCS ) HAS BEEN SET UP

    PACKING STANDARD IS DISPLAYED AND


    PACKING/ IMPROPER SHORTAGE/EXCESS PACKING NOT DONE AS PER
    10 YC 3 PERIODICALLY BRAINSTORMING IS 2 60 NOT REQUIRED
    DISPATCH PACKING/DISPATCH OF MATERIAL STANDARD
    IMPARTED
    PACKING STANDARD IS DISPLAYED AND Packing
    WRONG PACKING DONE DUE 100% MANUAL COUNTING EACH PARTS
    FITMENT PROBLEM 10 YC 4 PERIODICALLY BRAINSTORMING IS 2 80 NOT REQUIRED Operator 10 3 3 90
    TO NEGLEGANCY OF OPT BEFORE DISPATCH
    IMPARTED and Officer
    PERIODICALLY BRAINSTORMING OF
    NEGLENGACY OF PACKING
    MIXING PROBLEM 10 YC 4 OPERATORS & REVERIFICATION BY QC 2 80 NOT REQUIRED
    OPERATOR
    SUP BEFORE DISPATCH

    Page 47 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/06-06-15

    Part Name.:- Auxiliary Outlet pipe assy Part Code:-3P346162-1F

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    NO ACTION RECOMMENDED IF RPN<100
    ACTION RECOMMENDED IF RPN>=150
    IMMEDIATE ACTION IF RPN>150
    RECOMMENDED
    Prepared By: Checked By: Approved BY:

    Page 48 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/06-06-15

    Part Name.:- Auxiliary Outlet pipe assy Part Code:-3P346162-1F

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    LENGTH
    FITMENT PROBLEM 10 YC IMPROPER SETTING OF M/C 4 M/C SET UP BY LINE SUPERVISOR 1 40 NOT REQUIRED 10 3 3 90
    SHORT/EXCESS

    ONLY CERTIFIED CUTTING OPERATOR


    IMPROPER SETTING OF FIRST OF SAMPLE CHECK SHEET IS Cutting IS ALLOWED TO CUTTING TRAINING
    CUTTING 3 1 30 NOT REQUIRED
    GUIDE ROLLER IMPLEMENTED. Operator HAS BEEN IMPARTED TO SKILLED
    OPERATOR
    APPERANCE NG
    FIRST OF SAMPLE CHECK SHEET AND 10 3 3 90
    VISUAL DEFFECT DENTS/SCRATCHES/ 5 YS DEFECTS IN CUTTING M/C DIE 4 2 40 NOT REQUIRED
    VISUAL INSPECTION IS IMPLEMENTED
    PINCHES
    WEAR & TEAR OF DIE 3 TOOL HISTORY CARD IMPLEMENTED 2 30 NOT REQUIRED
    EXTERNAL PARTICLES
    IMPROPER CLEANING FIRST OF SAMPLE CHECK SHEET IS
    DEBURRING BRAZING PROBLEM 4 OIL/COPPER CHIPS /GREASE 4 2 32 NOT REQUIRED EDUCATION AND TRAINING PROVID TO 10 3 3 90
    OF TUBE ENDS IMPLEMENTED
    OUTSIDE THE TUBE. Deburring DEBURRING OPERATOR REMOVE
    FULL/PARTIALLY EXTERNAL PARTICLES Operator BURRS ALL COPPER AND CAPILLARY
    FIRST OF SAMPLE CHECK SHEET IS TUBE.
    CHOCKING 5 OIL/COPPER CHIPS /GREASE 3 2 30 NOT REQUIRED 10 3 3 90
    IMPLEMENTED
    PROBLEM INSIDE THE TUBE.

    FORMING FITMENT PROBLEM ALL TOOLS HAVE BEEN PUNCHED MARKED


    EXPANDING DIMENSION PROBLEM WITH MATCHING 10 YC SPECIFIED TOOL NOT USED 2 /COLOR CODED; WI & TRAINING IS 2 40 NOT REQUIRED
    REDUCING PARTS IMPARTED
    GAUGE VERIFICATION & FIRST OFF
    Forming
    SAMPLE SHEET IMPLEMENTED EVERY 10 3 3 90
    WEAR & TEAR OF TOOLS 5 TOOL HISTORY CARD IS IMPLEMENTED 2 100 NOT REQUIRED Operator
    PARTS
    PRESSURE GAUGE DEPLOYED AND
    IMPROPER AIR PRESSURE 5 PERIODICALLY MONITORING IS 2 100 NOT REQUIRED
    IMPLEMENTED

    IMPROPER IMPROPER SETTING OF MC & M/C SET UP BY CNC TRAINED OPERATOR


    FITMENT PROBLEM 10 YC 3 2 60 NOT REQUIRED
    DIMENSIONING FIXTURE & VERIFIED BY PROD SUP

    Maual
    MANUAL / SPECIFIED MANDREL NOT TRAINING IS IMPARTED & FIRST OF bending JIG,FIXTURE VERIFICATION & FIRST
    3 1 30 NOT REQUIRED 10 3 3 90
    CNC BENDING USED SAMPLE CHECK SHEET IS IMPLEMENTED and CNC OFF SAMPLE SHEET IMPLEMENTED
    Operator

    PROPERLY PLACING OF BENDED PART


    APPERANCE NG
    DENTS/ SCRATCHES/ IMPROPER HANDLING/ INTO TROLLY AS PER STANDARD / FIRST
    DENTS/SCRATCHES/ 5 YS 4 4 80 NOT REQUIRED
    PINCH DEFECTS IN DIE OFF SAMPLE CHECK SHEET IS
    PINCHES
    IMPLEMENTED

    EXTERNAL PARTICLES TCE SOLUTION CHANGE FREQUENCY IS


    T.C.E.
    IMPROPER CLEANING BRAZING PROBLEM 6 OIL/COPPER CHIPS /GREASE 2 DEFINED AS PER NO.OF PIECES WASHED 2 24 NOT REQUIRED EDUCATION AND TRAINING PROVID TO
    CLEANING
    OUTSIDE THE TUBE. & MONITORING SHEET IS MPLEMENTED Quality TCE OPERATOR REMOVE
    10 3 3 90
    FULL/PARTIALLY EXTERNAL PARTICLES Inspector BURRS,DUST,OIL ALL COPPER AND
    TCE SOLUTION CHANGE FREQUENCY IS CAPILLARY TUBE.
    CHOCKING 6 OIL/COPPER CHIPS /GREASE 2 2 24 NOT REQUIRED
    DEFINED AS PER NO.OF PIECES WASHED.
    PROBLEM INSIDE THE TUBE.

    PROD
    FIXTURE VERIFICATION wrt FINAL
    IMPROPER ALL FIXTURE HAS BEEN MARKED & COLOR ENGG FIXTURE VERIFICATION & FIRST OFF
    BRAZING FITMENT PROBLEM 10 YC BRAZING FIXTURE NOT OK 4 4 160 FITMENT JIG TO BE IMPLEMENTED 10 3 3 90
    DIMENSIONING CODED SUNDARL SAMPLE SHEET IMPLEMENTED
    BEFORE STARTING THE PRODN
    AL

    ONLY TRAINED OPERATOR TO BE


    PROD ONLY CERTIFIED BRAZER IS ALLOWED
    ONLY SKILLED & SEMISKILLED ALLOWED TO BRAZE & PERIODICALLY
    IMPROPER BRAZING ENGG TO BRAZE & BRAZER TRAINING HAS
    LEAKAGE/CHOCKING 10 YC UNTRAINED OPERATOR 4 OPERATORS ARE PERFORMING BRAZING 4 160 TRAINING SYSTEM TO BE 10 3 3 90
    LESS/EXCESS SUNDARL BEEN IMPARTED TO SEMI SKILLED
    OPERATION. IMPLEMENTED TO SEMI SKILLED OPT
    AL BRAZER
    TO MAKE THEM TRAINED

    RED BIN LOCATION MUST BE UNDER RED BIN LOCATION IS DEFINED, ITS
    SKIPPING OF LEAK PCS & TABLE & LEAKE PORTION TO BE RED QC ENGG USAGE TRAINING HAS BEEN IMPARTED
    LEAK TESTING IMPROPER TESTING GAS LEAKAGE 10 YC 4 RED BIN SYSTEM IS IMPLEMENTED 3 120 10 3 3 90
    MIXED UP WITH OK PCS MARKED & TRAINING HOW TO USE RED VINOD & RED MARKING AT THE LEAK
    BIN TO BE IMPARTED PORTION IS IMPLEMENTED

    STRICTLY RECOMMENDED HIGHLY


    TRAINED OPERATOR TO PERFORM ONLY CERTIFIED LEAKAGE TESTING
    THIS OPERATION AND PERIODICALLY OPERATOR IS ALLOWED TO TEST &
    IMPROPER PRESSURE & TRAINING TO THEM & SEMI-SKILLED QC ENGG PERIODICALLY TRAINING IS IMPARTED.
    5 TRAINED OPERATOR APPOINTED 4 200 10 3 3 90
    TESTING TIME OPERATOR MUST BE IMPARTED & VINOD AIR PRESSURE GUAGE IS LOCATED AT
    PRESSURE GAUGE MUST BE LOCATED EACH STATION AND MONITORING
    ON EACH STATION & MONITORING SHEET IS IMPLEMENTED
    MUST BE DONE

    MINERAL OR RO-WATER TO BE USED RO WATER IS IMPLEMENTED &


    DIRECT TAP WATER IS USED & CHANGE QC ENGG
    CONDITION OF WATER 4 4 160 AND WATER CHANGE FREQUENCY TO CHANGE FREQUENCY IS VISUAL 10 3 3 90
    FREQUENCY IS BASED ON VISUAL DURGESH
    BE REVIEWED BASED

    100% CHOCK TEST TO BE DONE WITH PROD


    CHOCK SKIPPING OF CHOCKED PCS WATER ANOTHER SIDE & MUST BE ENGG 100% CHOCK TEST IS IMPLEMENTED
    IMPROPER TESTING GAS FLOW STOP 10 YC 4 NO CHOCK TEST IS PERFORMED 4 160 10 3 3 90
    TESTING & MIXED UP WITH OK PCS CONTROLLED BY CODING/MARKING ON SUNDARL WITH MARKING
    EACH PART AL

    IMPROPER
    IMPROPER AIR MOISTURE PRESENT IN THE PRESSURE GUAGE & AIR BLOWING TIME
    WATER DRYING FUNCTIONNING OF 7 3 2 42 NOT REQUIRED NA
    BLOWING TUBE PERIOD MAINTAINED
    COMPRESSOR Operator
    MOISTURE PRESENT IN THE DAILY MONITORING PROCESS CHECK
    RUSTING OF TUBES 5 3 2 30 NOT REQUIRED NA
    TUBE SHEET HAS BEN IMPLEMENTED.
    IMPROPER PERIODICALLY TRAINING PROVIDED TO ONLY TRAINED OPERATOR MUST
    FINAL FITMENT FITMENT PROBLEM 8 NEGLEGANCY OF OPERATOR 3 3 72
    CHECKING/FITMENT OPERATOR. PERFORM THIS PROCESS Quality
    ALL FINAL FITMENT JIG CALIBRATED 10 3 3 90
    WEAR & TEAR OF FITMENT PERIODICALLY JIG VERIFICATION IS Inspector
    3 2 48 NOT REQUIRED
    ZIG IMPLEMENTED
    IMPROPER COPPER CHIPS/EXTERNAL
    CHOCKING BLOWING PRESSURE STD (5-6 KG/CM2) &
    N2 BLOWING /INSUFFICIENT N2 7 PARTICLES REMAIN INSIDE 3 2 42 NOT REQUIRED NA
    PROBLEM TIME (5-10 SEC/PCS ) HAS BEEN SET UP
    FLUSHING TUBE
    Operator
    MOISTURE PRESENT IN THE BLOWING PRESSURE STD (5-6 KG/CM2) &
    FUCTIONING NOT OK 7 3 2 42 NOT REQUIRED NA
    TUBE TIME (5-10 SEC/PCS ) HAS BEEN SET UP

    PACKING STANDARD IS DISPLAYED AND


    PACKING/ IMPROPER SHORTAGE/EXCESS PACKING NOT DONE AS PER
    10 YC 3 PERIODICALLY BRAINSTORMING IS 2 60 NOT REQUIRED
    DISPATCH PACKING/DISPATCH OF MATERIAL STANDARD
    IMPARTED
    PACKING STANDARD IS DISPLAYED AND Packing
    WRONG PACKING DONE DUE 100% MANUAL COUNTING EACH PARTS
    FITMENT PROBLEM 10 YC 4 PERIODICALLY BRAINSTORMING IS 2 80 NOT REQUIRED Operator 10 3 3 90
    TO NEGLEGANCY OF OPT BEFORE DISPATCH
    IMPARTED and Officer
    PERIODICALLY BRAINSTORMING OF
    NEGLENGACY OF PACKING
    MIXING PROBLEM 10 YC 4 OPERATORS & REVERIFICATION BY QC 2 80 NOT REQUIRED
    OPERATOR
    SUP BEFORE DISPATCH

    Page 49 of 50
    ISPM PROCESS FAILURE MODE & EFFECT ANALYSIS - PFMEA REV/DATE : 01/06-06-15

    Part Name.:- Auxiliary Outlet pipe assy Part Code:-3P346162-1F

    OCCURRENCE

    OCCURRENCE
    DETECTION

    DETECTION
    PROCESS POTENTIAL FAILURE POTENTIAL FAILURE

    RISK PN
    SEVERITY

    SEVERITY
    POTENTIAL CAUSES CURRENT CONTROL ACTION RECOMMENDED RESP. ACTION TAKEN
    STEP/INPUT MODE EFFECTS

    RISK PN
    CLASS
    NO ACTION RECOMMENDED IF RPN<100
    ACTION RECOMMENDED IF RPN>=150
    IMMEDIATE ACTION IF RPN>150
    RECOMMENDED
    Prepared By: Checked By: Approved BY:

    Page 50 of 50

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