PROCESS/PRODUCT FAILURE MODES and EFFECTS ANALYSIS(FMEA)

PROCESS/PRODUCT FAILURE MODES and EFFECTS ANALYSIS(FMEA)

Process/Product Failure Modes and Effects Analysis (FMEA)
The process of casting of aluminum products / 08/07/2014
Team Manager: S. Shpak.
Team: Production Manager, A.Astafyev;Chief Engineer V. Brik;Senior Foreman of Casting Department,Т. Khorunzha;Mechanical Technician,А.Kuzmin; Chief Power Engineering Specialist,V. Vovk; Head of Technical Control Department, V.Polyakov.
In case of RPN > 100 - mandatory modification of the design (technology) is required
Product (Process)/
Function / Failure Mode / Failure Effects / “S” Significance / Failure Cause or Mechanism / “О”Occurrence / Initial Measures to Prevent the Failure (Causes) / Initial Measures to Identify the Failure (Causes) / “D” Detection / RPN (risk priority number) / Actions
Recommended / Responsibility and Planned Date / Results of Actions
Actions Taken / New points value
S / O / D / R
P
N
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11
Casting of Aluminum Products / Sticking of castings / Reject as defective moulding; breakage of mould; productivity slowdown / 8 / Improper lubrificant: by brand, concentration, uniformity of the application / 4 / Casting Control Chart, personnel training / Foreman control / 3 / 96 / To develop the regulation / Т. Khorunzha 28/07/14
8 / The temperature of an alloy mismatch the Casting Control Chart, / 3 / Maintainthe temperature specified in Casting Control Chart, / Foreman control / 3 / 72
8 / Scratches on the mould as a result of uncareful cleaning by caster / 1 / Training of caster / Foreman control / 6 / 48
Breakage of mould components / 100% of non conforming products without sorting; impossibility of manufacture / 8 / Metal fatigue / 2 / Count the number of shots made by mould / Statistics of breakdowns / 3 / 48
Mechanical Treatment / Notch, rough cleaning (mismatch the Control Chart) / Visible defect on the painted surface / 8 / Worn cleaning tool / 2 / Monitoring by operator / Monitoring by technical control department / 1 / 16
Incorrect thread / Customer unable to assemblе parts / 8 / Worn, broken tool / 3 / Monitoring by operator (each part) / Monitoring by technical control department(10%) / 1 / 24