Process/Product

Alucast Ltd Quality Control

Failure Modes and Effects Analysis
(FMEA)

Process or
Product Name:
1234B ROTOR COVER Prepared by: R. Gutteridge Paul McMichael

Responsible: R. Gutteridge, D. Hall, G. Woods FMEA Date (Orig) _12/12/01____________ (Rev) _01____________

Process S O D R S O D R
Step/Part E C E P E C E P
Number Potential Failure Mode Potential Failure Effects V Potential Causes C Current Controls T N Actions Recommended Resp. Actions Taken V C T N
Poor Finish, Insufficient
Goods Inward Supplier error, Fork truck Full spec with delivery, Every Tighter controls on Fork truck
Metal Out of Spec strength customer 7 3 7 147 Metal booked out of stores 7 2 2 28
Metal driver error ingot colour coded metal movement operative
complaint
Poor Finish, Insufficient 10% audit on incoming
Goods Inward Tighter controls on Snr. Quality
Metal Out of Spec strength customer 7 Supplier error 3 QA cert with every delivery 7 147 ingot carried out at 7 1 2 14
Metal metal quality Engineer
complaint independant lab.
Die Damage , Down time Only used Person
Die tooling In-adequate material Poor design In-adequate Approved suppliers list
production loss, customer 7 4 Vendor rating G.A. preparation 7 196 experienced purchasing 7 1 3 21
procurement used in manufacture preparation drawn up
complaint approved tool makers tooling
Late delivery of tooling, late
Die tooling Poor tool maker, equipment
Dimensionally incorrect start to production, 7 1 Vendor Rating I.S.I.R. 2 14 0
procurement out of calibration
customer concern
Misruns, Coldshuts, NCU, Monitor casting temps Quality
Casting Temp. Too Cold 7 Operator Error 5 Process control sheet 3 105 Procedure drawn up 8 2 3 48
Customer concern daily Engineer
Porosity after finishing
Monitor casting temps Quality
Casting Temp. Too Hot operation, Loss production, 7 Operator Error 6 Process control sheet 3 126 Procedure drawn up 7 6 3 126
daily Engineer
Customer complaint
Loss of production, short
Poor operator control, poorly Operator experience G.A.
Clipping Clipping Damage fall at finishers, customer 7 2 3 42 0
designed clipping tool preparation
complaint
Viewer error unaware of Final View sheet Sheets updated using
Final
Final View Unacceptable castings to Various 7 acceptance standard agreed 4 Final View Process 4 112 updated, Digital digital images to high light 8 3 1 24
Viewers
with customer Images to be used potential problems

0 0

Issue No. 2 Issue Date: 1st August 2001 AQC 18