06/03/202215:37:20 SFO TECHNOLOGIES PVT LTD

MECHANICAL DIVISION, BANGALORE

SFO TECHNOLOGIES PVT LTD - MECHANICAL DIVISION
FAILURE MODE AND EFFECTS ANALYSIS
Team Members:
Customer: Doc Number:
Part No & Rev.: Origin Date:
Part Description: Welding(SMAW/GMAW/GTAW/RSW) Revised Date:
Drawing No Rev.: -- Page No. 1 of 2

Classification

Revised Sev
Occurrence
Current Current Responsibility

Detection
Severity
Process No. Potential Potential
Process/ Function/ Potential Failure Process Process Recommended & Target Actions Taken

RPN
(Defect Effect(s) Causes(s)
Requirement Mode Controls Controls Action Completion & Effective Date
Code) of Failure of Failure
Prevention Detection Date

No other grade filler Use Filler wire

Use of different grade of Established WPS and
10 3 material issued to the 1 30 grade as per Production
filler material Procedure Qualification
Poor strength& welder. WPs.
100/104 Crack/Crater Crack
Functional failure. Use welding parameters Weld on test sample
Use of high current(Lead to
10 3 specified in the WPS before doing full 1 30
hot crack)
only. welding.

Poor strength 7 Weld surface contaminated 4 Welder/

Weld surface is cleaned 100% Visual Inspection 2 56 Clean the weld
2017 Surface Pores with dust/oil/dirt/paint stains Welding
with wire brush. of joints to be welded. surface.
etc. Operator
Aesthetics 6 4 2 48

Re weld at the start/stop 100% Visual inspection

2025 End Crater Pipe Functional Failure 8 Poor Restart/stop. 5 points ater the under bright light with 2 80 Drop weld at the Welder
completion of weld. min 500 lux. beginning & end
of every weld.

Welding parameters
10 5 are followed as per 5 250
WPS requiements.
Pracice on test
Lack of Functional Welds of similar joints
Use of lower sample before
401 Fusion/Incomplete Failure/Poor validated through Conduct Macro Welder
amperage/voltage doing full
Fusion Strength WPQR. Examination at regular welding.
10 5 intervals(6 months) to 1 50
determine the weld
fusion/penetration.

Mock-up test is being

Sample test coupon
carried out and checked
10 3 welded and tested by 5 150
for penetration by
fracture test internally.
fracture test.
Pracice on test
Poor
Incomplete Root Use of insufficient welding sample before
4021 strength/Functional Welder
Penetration current/voltage/wire speed. doing full
failure. Once in 6 months, Conduct Macro
welding.
similar weld test coupon Examination at frequent
10 4 is being checked in intervals(6 months) to 1 40
external laboratory for determine the root
Macro Examination. penetration.

Use righ dia

Poor Before start of welding,
Established WPS and electrode & the
5011/5012 Undercut strength/Functional 10 High current/ voltage 3 test on a sample/ unused 3 90 Welder
Procedure Qualification root gap is not
failure. material.
wide.

For thinner sheet metals, Open the

a root gap as prescribed Established WPS and groove by
5013 Shrinkage Groove Poor Strength 6 Narrow root gap 4 3 72 grinding if the Welder
in WPS is being Procedure Qualification
Welding(SMAW/GMAW/ followed. root gap is
GTAW/RSW) narrow.

Printed Documents without control copy stamp in red color, are for Reference Only and may be out-of-date. Check the database to ensure you have the correct revision. Format No. SFE47.005 Rev 2.0
06/03/202215:37:20 SFO TECHNOLOGIES PVT LTD
MECHANICAL DIVISION, BANGALORE
SFO TECHNOLOGIES PVT LTD - MECHANICAL DIVISION
FAILURE MODE AND EFFECTS ANALYSIS
Team Members:
Customer: Doc Number:
Part No & Rev.: Origin Date:
Part Description: Welding(SMAW/GMAW/GTAW/RSW) Revised Date:
Drawing No Rev.: -- Page No. 1 of 2

Classification

Revised Sev
Occurrence
Current Current Responsibility

Detection
Severity
Process No. Potential Potential
Process/ Function/ Potential Failure Process Process Recommended & Target Actions Taken

RPN
(Defect Effect(s) Causes(s)
Requirement Mode Controls Controls Action Completion & Effective Date
Code) of Failure of Failure
Welding(SMAW/GMAW/ Prevention Detection Date
GTAW/RSW)
Maintain the
excessive current, too slow Check visually 100% by Fiollow welding
travel speed
502 Excess Weld Metal Aesthetics 5 travel speeds and incorrect 6 certified welding parameters mentioned 3 90 Welder
within the wps
joint fit-up inspectors. in WPS.
range.

Use appropriate welding Weld on a test

amperages, manipulation Fiollow welding sample and
Excessive Improper welding
503 Poor strength 6 3 speeds, arc lengths (arc parameters mentioned 3 54 check before Welder
Convexity parameters.
voltages), electrode in WPS. doing full
travel and work angles. welding.

Use appropriate welding Use

Joint gap is too large, root Fiollow welding
Cause erosion and current/voltage, position current/voltage
504 Excess Penetration 8 faces are too small or heat 4 parameters mentioned 2 64 Welder
corrosion problems wrt thicknesses and weld within WPS
input that is too high in WPS.
on sample test piece. range.

Welding sequence Intermittent welding Follow weld

Asthetic. 3 Continuous Welding 3 3 27 Welder
followed. sequence followed. map sequence.

-- Distorsion
Follow welding Develop
Welding sequence not Welding sequence/weld
6 3 sequence as per weld 2 36 jigs/fixtures
correct/not followed. map is being followed.
Assembly map. wherever
Welder/
Issue/Improper Welding possible from
Welding is being Production
fitment. Suitable jigs/fixtures not jigs/fixtures/clamps are the child part
6 3 performed by clamping 2 36 welding stage
used. being used on the work
the product. itself.
table.
Cannot meet GD &
T dimensions Weld intermittent weld. 2
requirements

Weld the job at

Weld on test sample and Check weld size by
505 Incorrect weld Toe Poor Strength 8 Improper welding Position. 3 3 72 an appropriate Welder
check with fillet gauge using fillet gauge.
position.

Welding Check the joint

Welding is being
Not used welding jigs/fixtures/clamps are alignment
506 Overlap Poor joint strength 8 3 performed by clamping 2 48 Welder
fixtures/clamps. being used on the work visually before
the product.
table. welding.

Less arc current and faster

8 4 2 64
Sagging/ arc travel speed. Maintain current and Verify in-process quality
Reduce ravel
509/511 Incompletely filled Poor Strength travel speed as per documents by QA Welder
Speed.
groove relevant WPS. engineer.

Printed Documents without control copy stamp in red color, are for Reference Only and may be out-of-date. Check the database to ensure you have the correct revision. Format No. SFE47.005 Rev 2.0
06/03/202215:37:20 SFO TECHNOLOGIES PVT LTD
MECHANICAL DIVISION, BANGALORE
SFO TECHNOLOGIES PVT LTD - MECHANICAL DIVISION
FAILURE MODE AND EFFECTS ANALYSIS
Team Members:
Customer: Doc Number:
Part No & Rev.: Origin Date:
Part Description: Welding(SMAW/GMAW/GTAW/RSW) Revised Date:
Drawing No Rev.: -- Page No. 1 of 2

Classification

Revised Sev
Occurrence
Current Current Responsibility

Detection
Severity
Process No. Potential Potential
Process/ Function/ Potential Failure Process Process Recommended & Target Actions Taken

RPN
(Defect Effect(s) Causes(s)
Requirement Mode Controls Controls Action Completion & Effective Date
Code) of Failure of Failure
Prevention Detection Date
Sagging/ Maintain current and Verify in-process quality
Reduce ravel
509/511 Incompletely filled Poor Strength Too large electrode travel speed as per documents by QA Welder
Speed.
groove 8 diameter and longer arc 4 relevant WPS. engineer. 2 64
length.

Weld on a test sample

excessive heat input and before welding on
10 3 2 60
Poor travel speed. Welding is being actual part.
510 Burn Through strength/Functional performed as per WPS Welder
failure. requirements. Use
Inspect visually by the current/voltage
10 lower weld angle 3 welder and welding 2 60 within WPS
inspectors. range.

Use appropriate welding

Excessive amperages, manipulation Fiollow welding Weld at an
Improper welding
512 Assymetry of fillet Poor strength 6 3 speeds, arc lengths (arc parameters mentioned 3 54 appropriate Welder
parameters.
welds voltages), electrode in WPS. torch angle
travel and work angles.

Use appropriate welding

Fiollow welding
Excessively high welding amperages and speed
515 Root Concavity Poor strength 6 3 parameters mentioned 3 54
speeds. on the test sample and
in WPS.
check.
All weld parts are
Weld joint are either
Improper cleaning of weld cleaned by wire
516 Root Porosity Poor strength 6 3 ground or polished by 2 36
joint. brush/grinding before
scrubber.
welding.
Fiollow welding
Insufficient Throat Improper welding Weld on test sample and
5213 Poor strength 6 3 parameters mentioned 2 36
Thickness parameters. check with fillet gauge
in WPS.

Use appropriate welding

amperages, manipulation Fiollow welding
Excessive Throat Improper welding
5214 Poor strength 6 3 speeds, arc lengths (arc parameters mentioned 3 54
Thickness parameters.
voltages), electrode in WPS.
travel and work angles.

1. Apply anti
spatter on the
Fiollow welding joint to be
Use welding parameters
6 Use of low voltage 4 parameters mentioned 2 48 welded.
as per WPS.
in WPS. 2. Use voltage
602 Spatter Aesthetics Welder
suitable for the
plate thickness.
3. Clean the
surface of the
filler wire.
Printed Documents without control copy stamp in red color, are for Reference Only and may be out-of-date. Check the database to ensure you have the correct revision. Format No. SFE47.005 Rev 2.0
06/03/202215:37:20 SFO TECHNOLOGIES PVT LTD
MECHANICAL DIVISION, BANGALORE
SFO TECHNOLOGIES PVT LTD - MECHANICAL DIVISION
FAILURE MODE AND EFFECTS ANALYSIS
Team Members:
Customer: Doc Number:
Part No & Rev.: Origin Date:
1. Apply anti
Part Description: Welding(SMAW/GMAW/GTAW/RSW) spatter on the Revised Date:
joint to be
Drawing No Rev.: -- welded. Page No. 1 of 2
2. Use voltage

Classification

Revised Sev
602 Spatter Aesthetics Welder

Occurrence
Current Current suitable for the Responsibility

Detection
Severity
Process No. Potential Potential
Process/ Function/ Potential Failure Process Process Recommended
plate thickness. & Target Actions Taken

RPN
(Defect Effect(s) Causes(s)
Requirement Mode Controls Controls Actionthe
3. Clean Completion & Effective Date
Code) of Failure of Failure
Prevention Detection Date
surface of the
filler wire.
Scrub the weld joint Use anti spatter on the
weld Surface/filler wire not
6 4 surface using scrubber joints wherever 2 48
cleaned.
or grinding. possible.

Holder, or current return Place the welding holder A holder device has
6 clamp have accidentally 4 on the stand away from been put on the 2 48
touched the work the work during welding. machine.
601 Stray Arc Aesthetics
Fasten the earthing Earthing cables are
6 Earthing clamp is loose 4 cable firmly to the work firmly clamped at the 2 48
table. base of the work table.

Prepare a laser cut

Stitch length not
-- Asthetic. 6 Not used template 3 template to locate the Template in use. 2 36
even
stitch welds.
Note: Reference: Welding Quality imperfection levels in accordance with ISO 5817 & ISO 10042.

Printed Documents without control copy stamp in red color, are for Reference Only and may be out-of-date. Check the database to ensure you have the correct revision. Format No. SFE47.005 Rev 2.0
 06/03/202215:37:20 SFO TECHNOLOGIES PVT LTD
PVT LTD - MECHANICAL DIVISION
MECHANICAL DIVISION, BANGALORE
DE AND EFFECTS ANALYSIS

1 of 2

Revised Detect

Revised R.P.N.
Revised Occur

Printed Documents without control copy stamp in red color, are for Reference Only and may be out-of-date. Check the database to ensure you have the correct revision. Format No. SFE47.005 Rev 2.0
 06/03/202215:37:20 SFO TECHNOLOGIES PVT LTD
PVT LTD - MECHANICAL DIVISION
MECHANICAL DIVISION, BANGALORE
DE AND EFFECTS ANALYSIS

1 of 2

Revised Detect

Revised R.P.N.
Revised Occur

Printed Documents without control copy stamp in red color, are for Reference Only and may be out-of-date. Check the database to ensure you have the correct revision. Format No. SFE47.005 Rev 2.0
 06/03/202215:37:20 SFO TECHNOLOGIES PVT LTD
PVT LTD - MECHANICAL DIVISION
MECHANICAL DIVISION, BANGALORE
DE AND EFFECTS ANALYSIS

1 of 2

Revised Detect

Revised R.P.N.
Revised Occur

Printed Documents without control copy stamp in red color, are for Reference Only and may be out-of-date. Check the database to ensure you have the correct revision. Format No. SFE47.005 Rev 2.0
 06/03/202215:37:20 SFO TECHNOLOGIES PVT LTD
PVT LTD - MECHANICAL DIVISION
MECHANICAL DIVISION, BANGALORE
DE AND EFFECTS ANALYSIS

1 of 2

Revised Detect

Revised R.P.N.
Revised Occur

Printed Documents without control copy stamp in red color, are for Reference Only and may be out-of-date. Check the database to ensure you have the correct revision. Format No. SFE47.005 Rev 2.0