Galva POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PFMEA)

Format / Doc. No. : GD3-F-QA-04

Rev No : 00
Rev. Date : 01.01.2019
Process Responsibility: Mr.Rajesh Bhutada (Moulding) PFMEA No.: GDPL/PFMEA/MLD/BAJAJ
Item: EMBLEM BAJAJ Mr. D Dinesh Prepared by:Mr.Sambhu Pr. Sahu

Model Year(s)/Vehicle(s) : BAJAJ Key Date:12.10.2021 Date (Orig.):12.10.2021

Mr. V Ramesh(Quality Functions), Mr. Dinesh/ Mr. Ashish P ( Mld. Quality/Moulding),Mr. Surendra Saini (Tooling) , Mr. Avanish Kumar Up /Mr. Pawan Th/ Mr. Sujit(Plating), Mr. Raghuvir (Jigging),
Core Team: Rev No/ Date :01/25.10.2023
Mr. Manish (Jig Mfg.), Mr. Hanumanth/ Ms. Priyanka (Testing), Mr. Ankit/Mr. Chandan T (PPC/SCM) , Mr. Ravi B/Mr. Lokesh /Mr. Abhishek (New Projects),Mr. C.S. Rawat (Operation Head)

Occurance (O)

Occurance (O)
Detection ( D)

Detection ( D)
Potential Responsiblity

Severity ( S )

Severity ( S )
Current Process Action taken R

=S*O*D
Op. Potential Potential Effect(s) of Cause's)/ Current Process Control Recommended & Target

RPN
Class
Process Step / function Requirements Control & Eeffective P
No. Failure Mode Failure Mechanism's) Prevention Actions completion
Detection Date N
of Failure Date

01. Poor Packing

Raw Material
1. Packing Damage of Material used by
Free from packing NP : RM bag rejected Inspection Report
R/M Bag received from supplier
damage of R/M Bag CE: Part Rejected 7 2 (GD1-F-QA-13). Visual inspection 7 98
RM Supplier during 2.Improper Handling
during receipt UE :N.A.
receipt of RM Bag during
transist

2.Supplier MTC not

NP : RM bag rejected RM material received
Raw material received matched with material verification of supplier
CE: Part Rejected 7 from supplier with 2 Feedback to Supplier 6 84
with right Supplier TC name of supplier MTC
UE :N.A. wrong MTC
Invoice

NP : RM bag rejected
3. Not in proper Wrong packing from
Proper Packing CE: Part Rejected 7 2 Inform to RM Supplier Visual inspection 6 84
packing raw material supplier
UE :N.A.

NP : RM bag rejected Training given to

Proper Handling of RM 4.Not proper handling 04. Wrong method of
CE: Part Rejected 6 2 loading/un loading Visual inspection 6 72
during receipt of RM during receipt handling
UE :N.A. person

NP: Unable to meet

production plan
5 Wrong grade RM Wrong grade suplied
Grade of RM as per PO (Delay in production) 7 2 Verify with supplier TC Visual inspection 7 98
receipt against PO by supplier
CE:Dealy in despatch
UE :N.A.

Verification of Raw Material

NP : Part rejected supplier Raw Material Inspection Report
Wrong grade suplied
Raw material Grade Wrong RM Grade CE: Part Rejected 7 2 Test Certificate as per (GD3-F-QA-06). 7 98
by supplier
UE : N.A. RM In-coming Quality
Plan
Raw material receipt
10
& Inspection
Verification of Raw Material
NP : Part rejected supplier Raw Material Inspection Report
Wrong MFI RM
MFI as per TC MFI not as per TC CE: Part Rejected 7 2 Test Certificate as per (GD3-F-QA-06). 7 98
suplied by supplier
UE : N.A. RM In-coming Quality
Plan
 Verification of Raw Material
NP : Part rejected Wrong HDT-Heat supplier Raw Material Inspection Report
HDT-Heat Deflection HDT-Heat Deflection
CE: Part Rejected 7 Deflection temp RM 2 Test Certificate as per (GD3-F-QA-06). 7 98
temp as per TC temp not as per TC
UE : N.A. suplied by supplier RM In-coming Quality
Plan

Verification of Raw Material

NP : Part rejected Wrong IZOD Impact supplier Raw Material Inspection Report
IZOD Impact Strength IZOD Impact Strength
CE: Part Rejected 7 Strength suplied by 2 Test Certificate as per (GD3-F-QA-06). 7 98
as per TC not as per TC
UE : N.A. supplier RM In-coming Quality
Plan

Raw Material
NP : Part rejected Wrong Specify Gravity Inspection Report
Specify Gravity not as
Specify Gravity CE: Part Rejected 7 RM supplied by 2 (GD1-F-QA-13). 7 98
per TC
UE : N.A. supplier

Raw Material
NP : Part rejected Verification of Inspection Report
Free from Moisture
Moisture Content CE: Part Rejected 7 Due to wet of RM Bag 2 supplier Raw Material (GD1-F-QA-13). 7 98
Content
UE : N.A. Test Certificate

Verification of Raw Material

Raw Material
NP : Part rejected supplier Raw Material Inspection Report
Other parameter , if Parameters out of
Other, if any CE: Part Rejected 7 2 Test Certificate as per (GD1-F-QA-13). 7 98
any specification ( MFI, Ash
UE : N.A. RM In-coming Quality
content etc.)
Plan

NP : Part rejected
Proper storage of Raw Improper Storage of No define loaction for Skill matrix of store
CE: Part Rejected 6 2 Visual Inspection 7 84
Material at location RM at location each raw material person
UE : N.A.
NP : Part rejected
No FIFO System in raw Skill matrix of store
Storage of RM as FIFO FIFO not followed. CE: Part Rejected 7 2 Visual Inspection 6 84
material storage person
UE : N.A.
NP : Part rejected
Free from Mix up of No identification on
Mix up grades CE: Part Rejected 7 2 Identification on Racks Visual Inspection 6 84
grade each racks
UE : N.A.
NP : Part rejected
20 Raw Material Storage Free from used of No FIFO System in raw Proper Location for
expired material used CE: Part Rejected 6 2 Visual Inspection 6 72
expired material material storage storage
UE : N.A.
NP : Part rejected
Free from used of No identification on
wrong grades used. CE: Part Rejected 7 2 Identification on Racks Visual Inspection 6 84
wrong grade Material each racks
UE : N.A.

NP:Delay in production No identification on Proper Identification

RM Storage in define RM storage in wrong 7 2 Visual Inspection 7 98
CE:N.A. Racks on Racks
location location
UE: N.A.
6 Area not identified 2 Area to be identified Visual Inspection 6 72
Due to not mention
Correct grade Raw Visual inspection on
1. Wrong grade Raw NP : Part rejected the Raw materail Material issue
Material to be issued 7 2 raw material bags for 7 98
Material issued CE & UE: Part Rejected grade in Material Requisition slip
as per requisition slip RM grade
issued Requisition slip
Raw Material to be
issued as per NP: Unable to meet Counting issue due to
Issue of Material From requirement/requisitio Short / Excess Qty. production plan not followed RM Skill matrix of store
30 7 2 Counting 7 98
store to shop n slip issued CE : Delay in despatch requirement/requisitio person
(No short / Excess UE:N.A. n slip
Qty.)
1. Proper handling of
NP : RM bag rejected
RM Bags 1. Im-proper handling
(7) CE: Untrained store Skill matrix of store
2. No damage bag to of RM Bags 7 2 Visual insepction 7 98
Part (7) Rejected person person
be issued for 2. Damage bag issued
UE :N.A.
production
 N.P : part rejected due
to silver streaks visible
Visual inspection on
on the parts. (7)
No Moisture in RM Moisture in RM after Process parameter temperature controller
C.E : Customer dis- 7 Less preheating time 2 7 98
after pre-heating pre-heating sheet of Hoper dryer and
satisfaction (7)
de-humididifier
U. E : Customer dis-
satisfaction (7)
NP:Parts get rejected
due to poor asthetic
defecrts like silver
Visual inspection on
streaks (7) Excess Preheating Process parameter
No Excess pre-heating Excess pre-heating 7 2 temperature controller 7 98
C.E : Customer dis- temperature sheet
and de-humidifier
satisfaction (7)
Preheating of raw U. E : Customer dis-
40 satisfaction (7)
material
NP : part rejected due
to Loss of part
strength (7) Visual inspection on
Free from any Mosisture get calibration of temp Process parameter
C.E : Customer dis- 7 2 temperature controller 7 98
Mosisture entraped . entraped . controller sheet
satisfaction (7) and de-humidifier
U. E : Customer dis-
satisfaction (7)
NP: Part rejected due
to Shade/colour
variation (7) Visual inspection on
Excess Preheating Process parameter
Even processing un even processing C.E : Customer dis- 7 2 temperature controller 7 98
temperature sheet
satisfaction (7) and de-humidifier
U. E : Customer dis-
satisfaction (7)
Process parameter
7 1. Low injection speed 2 Visual inspection 7 98
sheet
N.P: Part rejected due 2. Low injection Process parameter
7 2 Mould Flow analysis 7 98
to asthetic defect (7) pressure sheet
C.E : Customer dis- 7 3. Improper get size 2 CAD Data of Mould Visual inspection 7 98
No Short mould Short mould
satisfaction (7) 4. Improper material
7 2 MFI Visual inspection 7 98
U. E : Customer dis- flow
satisfaction (7) 7 6. Less Melt temp. 2 RM data sheet/ PPS Visual inspection 7 98
7. Wrong Mould
7 2 CAD Data of Mould Visual inspection 7 98
design
NP: Part rejected due
to to asthetic defect
(7) C.E :
1. Improper material
Free from Weld lines Weld line Customer dis- 7 2 MFI Visual inspection 7 98
flow
satisfaction (7)
U. E : Customer dis-
satisfaction (7)
1. Improper Tooling
condition
Preventive Maintence
7 2. Due to Improper 2 Visual inspection 7 98
Record'
N.P: Part rejected due packing of moulded
to asthetic defect (7) part
Free from dent mark/ C.E : Customer dis- 2. Contamination/
Dent Mark/ Damage RM to be check before
Damage satisfaction (7) 7 forign particals in the 2 Visual inspection 7 98
loading on M/C
U. E : Customer dis- RM
satisfaction (7) 3. Improper Handling Proper Handling of the
7 2 Handling WI 7 98
of the parts parts
7 4. Improper Packaging 2 Packing std. Visual Insepction 7 98
Process parameter
7 1. Less Cooling time 2 Visual Inspection 7 98
sheet
N.P: Part rejected due 2. Wrong Mould
7 2 CAD Data of Mould Visual Inspection 7 98
to Fitment issue (7) design
C.E : Customer dis- Process parameter
No warpage Warpage 7 3. High mould temp. 2 Visual Inspection 7 98
satisfaction (7) sheet
U. E : Customer dis- Process parameter
7 4. Less Cycle time 2 Visual Inspection 7 98
satisfaction (7) sheet
Process parameter
7 5. Less Holding time 2 Visual Inspection 7 98
sheet
 Process parameter
7 1. High injection speed 2 Visual inspection 7 98
sheet
2. High injection Process parameter
N.P: Part rejected due 7 2 Visual inspection 7 98
pressure sheet
to Poor Asthetical
5. Wrong Mould
defects/ Fittment
7 design/ Improper 2 CAD Data of Mould Visual inspection 7 98
problem (7)
Free from Flash Flash Mould condition
C.E : Customer dis-
Process parameter
satisfaction (7) 7 6. High Mould temp. 2 Visual inspection 7 98
sheet
U. E : Customer dis-
satisfaction (7) 7 7. High MFI 2 RM data sheet As per RM Data Sheet 7 98

7 8. High Melt temp. 2 PPS Monitoring sheet Shade Variation part 7 98

Process parameter
7 1. Low injection speed 2 Visual inspection 7 98
sheet
2. Low injection Process parameter
7 2 Mould Flow analysis 7 98
N.P: Part rejected due pressure sheet
to to asthetic defect 7 3. Improper gate size 2 CAD Data of Mould Visual inspection 7 98
(7) C.E : 4. Improper material
7 2 MFI Visual inspection 7 98
Free from sink mark Sink Mark Customer dis- flow
satisfaction (7) 7 5. Less Melt temp. 2 RM data sheet/ PPS Visual inspection 7 98
U. E : Customer dis- 7 6. High Melt temp. 2 RM data sheet/ PPS Visual inspection 7 98
satisfaction (7) Process parameter
7 6. High Mould temp. 2 Visual inspection 7 98
sheet
7. Wrong Mould
7 2 CAD Data of Mould Visual inspection 7 98
design
1. Less Preheating Process parameter
7 2 Visual inspection 7 98
temp. time sheet

N.P: Part rejected due We are using

to to asthetic defect the standard
Process parameter
(7) C.E : 7 2. High speed 3 Visual inspection 7 147 nozzle size and 7 1 7 49
Free from Silver sheet
Silver streaks Customer dis- replace the
streaks
satisfaction (7) nozzle
U. E : Customer dis-
satisfaction (7) Process parameter
7 3. High Barrel temp. 2 Visual inspection 7 98
sheet
4. Improper Mould Process parameter Visual inspection (Air
7 2 6 84
design sheet Vent)
N.P: Part rejected due Process parameter
7 1. High speed 2 Visual inspection 7 98
50
Injection Moulding, First piece to to asthetic defect sheet
approval & in process inspection
(7) C.E : 2. Improper Mould Replace the
Free from flow marks Flow marks 7 3 CAD Data of Mould Visual inspection 7 147 7 1 7 49
Customer dis- temp MTC
satisfaction (7) Process parameter
7 3. Less Mould temp 2 Visual inspection 7 98
U. E : Customer dis- sheet
N.P: Part rejected due
1.Wrong grade Process parameter
to to asthetic defect 7 2 Visual inspection 7 98
material use sheet
(7) C.E :
Free from Shade
Shade Variation Customer dis-
Variation
satisfaction (7)
Process parameter
U. E : Customer dis- 7 2. Mixup Grade Use 2 Visual inspection 7 98
sheet
satisfaction (7)
Process parameter
7 1. High injection speed 2 Visual inspection 7 98
sheet
2. High injection Process parameter
N.P: Part rejected due 7 2 Visual inspection 7 98
pressure sheet
to Poor Asthetical
5. Wrong Mould
defects/ Fittment
7 design/ Improper 2 CAD Data of Mould Visual inspection 7 98
Free from Parting line problem (7)
Parting line flashFlash Mould condition
flash C.E : Customer dis-
Process parameter
satisfaction (7) 7 6. High Mould temp. 2 Visual inspection 7 98
sheet
U. E : Customer dis-
satisfaction (7) 7 7. High MFI 2 RM data sheet As per RM Data Sheet 7 98

7 8. High Melt temp. 2 PPS Monitoring sheet Shade Variation part 7 98

 N.P: Part rejected due
to asthetic defect (7)
C.E : Customer dis- 1.Improper Mould
Free from Rib Damage Rib Damage 7 2 CAD Data of Mould Visual inspection 7 98
satisfaction (7) condition
U. E : Customer dis-
satisfaction (7)

N.P: Part rejected due Preventive

7 1. Improper Handling 2 Visual inspection 7 98
to asthetic defect (7) maintenance of mould
C.E : Customer dis-
Free from scratches Scratches 7 2. Improper Packaging 2 Packing std. Visual inspection 7 98
satisfaction (7)
U. E : Customer dis-
satisfaction (7) 7 3. Improper Storage 2 Skill Matrix Visual inspection 7 98

1. Insufficient holding
7 2 PPS Monitoring sheet Visual inspection 7 98
pressure
N.P: Part rejected due
to Poor Asthetical
defects/ Fittment
problem (7)
Free From Pitting Mark Pitting 7 2. Less Mould temp 2 PPS Monitoring sheet Visual inspection 7 98
C.E : Customer dis-
satisfaction (7)
U. E : Customer dis-
satisfaction (7)

7 3.Low injection speed 2 PPS Monitoring sheet Visual inspection 7 98

7 1. Less Mould temp 2 PPS Monitoring sheet Visual inspection 7 98

N.P: Part rejected due

to Poor Asthetical
defects/ Fittment
problem (7)
Free from Dust Mark Dust Mark
C.E : Customer dis- 2. Less Preheating Process parameter
satisfaction (7) 7 2 Visual inspection 7 98
temp. time sheet
U. E : Customer dis-
satisfaction (7)

Lifter polished
3. Wrong Mould
and mtc
7 design/ Improper 3 CAD Data of Mould Visual inspection 7 147 7 1 7 49
corrected
Mould condition

N.P: Part rejected due

to asthetic defect (7)
Proper C.E : Customer dis- As per WI(GD3-WI-
Deflashing 7 Not as per limit sample 2 Visual inspection 7 98
Deflashing satisfaction (7) MLD-01)
U. E : Customer dis-
satisfaction (7)

60 Molding Inprocess Inspection

Free from Moulding N.P: Part rejected due

defects to asthetic defect (7)
Proper Degating & C.E : Customer dis- Process Parameter
Moulding defects 7 Not as per limit sample 2 Visual Insp. 7 98
Deflashing satisfaction (7) Sheet
Moulding Poor surface U. E : Customer dis-
finish satisfaction (7)
A FPA / LPA
NP : Part rejcted due
to Fitment issue (7)
Part weight as per C.E : Customer dis- Parts not as per Process Parameter
Excess / less weight 7 2 Weight monitoring 7 98
specifcation satisfaction (7) drawing Sheet
U. E : Customer dis-
satisfaction (7)
 Free from Moulding N.P: Part rejected due
Moulding defects
defects to asthetic defect (7)
Im-Proper Degating &
Hourly Running Proper Degating & C.E : Customer dis- Process Parameter
B Deflashing 7 Not as per limit sample 2 Visual Insp. 7 98
Report Deflashing , satisfaction (7) Sheet
Moulding Poor surface
Moulding Poor surface U. E : Customer dis-
finish
finish satisfaction (7)

N.P: Part Returned to

Less Qty. 7 No Packing Std. 2 Packing Std. Visual Insp. 7 98
mould shop. (7)

Std.Quanity per each

box as per Packing Std.
Packaging , Labelling
70 N.P: Part Returned to
& Send to store Excess Qty. 7 No Packing Std. 2 Packing Std. Visual Insp. 7 98
mould shop. (7)

Std. Labelling on ok Non-Std. Labelling on

C.E: Wrong supply (7) 7 No.Labelling Std. 2 Labeling ing Std. Visual Insp. 7 98
box ok box

REVISION HISTORY
Revision Level Revision Date Reason of revision Review by
0 12.10.2021 Initial Release CFT
1 25.10.2023 Inhouse Top 3 deffect action plan taken CFT

Prepared by: Nayan Approved by :- Dinesh Kumar