Page 1 of 23

RP Engineering Works

PROCESS FMEA
Item: Albero Shaft Process Responsibility: HOD (QA), HOD (Process Engg), HOD (Machining) FMEA Number RP-FMEA-ST-26

Part No. / Drg. No. 0.45950685or (Rev # h /(20/09/2023) Key Date: 28/09/2023 Prepared By: Mr.Ashutosh Yadav

Model Year(s) / Program - Core CFT Team: Nirdesh ,Sushil ,Om prakash. FMEA Date (Orig.) : 28/09/2023 Rev.Date # 00
Process Step
Current Process Action Results

Severity

Class

Occurrence

Occurrence
Potential Failure Resp. & Target

RPN
Detection

Detection
Requirement Potential Effect (s) of Failure Potential Causes / of failure Recommended Action

Severity
Mode completion date

RPN
Controls Prevention Controls Detection Actions Taken & completion date

Function
Next Opn.-High rej and accident during
machining opn.
Deputting other inspector, Separate Verification of inspection
Inspector absent, Overload & Measuring
Missed Customer Uses-Nil 5 measuring equipments (to a possible 3 status tag before picking 7
instruments not available
extent) material for machining

10 End User-Nil
Dimensional & Visual
INCOMING 105
Inspection Next Opn.-Defective items may not be
INSPECTION
caught and may pass for machining

Display of inspection plan at

Not as per plan Customer Uses-Nil 5 Inspection plan may not available Inspection plan to be deifined 3 7
working station.

End User-Nil

Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(488.30±0.20) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil

Next Opn.-Part may reject/unclean

Set-up approval, Inprocess
Over size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 3 Inspection & patrol 5 60
Inspection
End User-Nil
ID
(Ø8.00±0.10)
Next Opn.-May be impact on tool life
Set-up approval, Inprocess
Under size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 4 Inspection & patrol 5 80
20 Inspection
Center Facing End User-Nil

Next Opn.-Nil
Spindle Outness Monitoring, Centre Set-up approval, Inprocess
Runout
More Customer Uses-Nil 4 Center Height disturbed, Spindle outness height adjustment and minitoring during 3 Inspection & patrol 5 60
(0.15 )
setting Inspection
End User-Performance May Effect
Next Opn.-Nil
Spindle Outness Monitoring, Centre Set-up approval, Inprocess
Runout
More Customer Uses-Nil 4 Center Height disturbed, Spindle outness height adjustment and minitoring during 3 Inspection & patrol 5 60
(0.10)
setting Inspection
End User-Performance May Effect
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Center Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(R8.50 Type) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(487.25±0.205) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-May be impact on tool life

Set-up approval, Inprocess

Over size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 4 Inspection & patrol 5 80
Inspection
End User-Nil
OD
(Ø38.00±0.10)

Doc No. RPEW/F/QAD/13 Rev No. 00 Date 01/04/2021

 Page 2 of 23

RP Engineering Works

PROCESS FMEA
Item: Albero Shaft Process Responsibility: HOD (QA), HOD (Process Engg), HOD (Machining) FMEA Number RP-FMEA-ST-26

Part No. / Drg. No. 0.45950685or (Rev # h /(20/09/2023) Key Date: 28/09/2023 Prepared By: Mr.Ashutosh Yadav

Model Year(s) / Program - Core CFT Team: Nirdesh ,Sushil ,Om prakash. FMEA Date (Orig.) : 28/09/2023 Rev.Date # 00
Process Step
Current Process Action Results

Severity

Class

Occurrence

Occurrence
Potential Failure Resp. & Target

RPN
Detection

Detection
Requirement Potential Effect (s) of Failure Potential Causes / of failure Recommended Action

Severity
Mode completion date

RPN
Controls Prevention Controls Detection Actions Taken & completion date

Function
OD
(Ø38.00±0.10) Next Opn.-Part may reject/unclean

Set-up approval, Inprocess

Under size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 3 Inspection & patrol 5 60
Inspection
End User-Nil

Next Opn.-May be impact on tool life

Set-up approval, Inprocess

Over size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 4 Inspection & patrol 5 80
Inspection
End User-Nil
OD
(Ø43.00±0.10) Next Opn.-Part may reject/unclean

Set-up approval, Inprocess

Under size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 3 Inspection & patrol 5 60
Inspection
End User-Nil

Next Opn.-May be impact on tool life

Set-up approval, Inprocess

Over size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 4 Inspection & patrol 5 80
Inspection
End User-Nil
OD
(Ø49.00±0.10) Next Opn.-Part may reject/unclean

Set-up approval, Inprocess

Under size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 3 Inspection & patrol 5 60
Inspection
End User-Nil

Next Opn.-May be impact on tool life

Set-up approval, Inprocess

Over size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 4 Inspection & patrol 5 80
Inspection
End User-Nil
OD
(Ø64.50±0.10) Next Opn.-Part may reject/unclean

Set-up approval, Inprocess

Under size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 3 Inspection & patrol 5 60
Inspection
End User-Nil

Next Opn.-Nil
30
CNC Rough Programm monitoring by supervisor, Set-up approval, Inprocess
Radius Wrong insert, Programm disturbed
Turning 1st setup More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(R0.50±0.10)
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Radius Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(R0.50±0.10)
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(69.20±0.20) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(107.98±0.20) Wrong offset, Machine variation
PM, Scheduled PM Inspection
Doc No. RPEW/F/QAD/13 Rev No. 00 Date 01/04/2021
 Page 3 of 23
30
CNC Rough
Turning 1st setup
RP Engineering Works

PROCESS FMEA
Item: Albero Shaft Process Responsibility: HOD (QA), HOD (Process Engg), HOD (Machining) FMEA Number RP-FMEA-ST-26

Part No. / Drg. No. 0.45950685or (Rev # h /(20/09/2023) Key Date: 28/09/2023 Prepared By: Mr.Ashutosh Yadav

Model Year(s) / Program - Core CFT Team: Nirdesh ,Sushil ,Om prakash. FMEA Date (Orig.) : 28/09/2023 Rev.Date # 00
Process Step
Current Process Action Results

Severity

Class

Occurrence

Occurrence
Potential Failure Resp. & Target

RPN
Detection

Detection
Requirement Potential Effect (s) of Failure Potential Causes / of failure Recommended Action

Severity
Mode completion date

RPN
Controls Prevention Controls Detection Actions Taken & completion date

Function
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(107.98±0.20) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(154.25±0.20) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Chamfer Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(0.74±0.10X45°max )
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Radius Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(R0.80±0.10)
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Angle Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(30°±30')
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Spindle Outness Monitoring, Centre Set-up approval, Inprocess
Runout
More Customer Uses-Nil 4 Center Height disturbed, Spindle outness height adjustment and minitoring during 3 Inspection & patrol 5 60
(0.10)
setting Inspection
End User-Performance May Effect
Next Opn.-Nil
Spindle Outness Monitoring, Centre Set-up approval, Inprocess
Runout
More Customer Uses-Nil 4 Center Height disturbed, Spindle outness height adjustment and minitoring during 3 Inspection & patrol 5 60
(0.10)
setting Inspection
End User-Performance May Effect
Next Opn.-Nil
Spindle Outness Monitoring, Centre Set-up approval, Inprocess
Runout
More Customer Uses-Nil 4 Center Height disturbed, Spindle outness height adjustment and minitoring during 3 Inspection & patrol 5 60
(0.10)
setting Inspection
End User-Performance May Effect
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(24.30 Ref ) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(485.50±0.20) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-May be impact on tool life

Set-up approval, Inprocess

Over size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 4 Inspection & patrol 5 80
Inspection
End User-Nil
OD
(Ø26.40±0.10) Next Opn.-Part may reject/unclean

Set-up approval, Inprocess

Under size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 3 Inspection & patrol 5 60
Inspection
End User-Nil

Doc No. RPEW/F/QAD/13 Rev No. 00 Date 01/04/2021

 Page 4 of 23

RP Engineering Works

PROCESS FMEA
Item: Albero Shaft Process Responsibility: HOD (QA), HOD (Process Engg), HOD (Machining) FMEA Number RP-FMEA-ST-26

Part No. / Drg. No. 0.45950685or (Rev # h /(20/09/2023) Key Date: 28/09/2023 Prepared By: Mr.Ashutosh Yadav

Model Year(s) / Program - Core CFT Team: Nirdesh ,Sushil ,Om prakash. FMEA Date (Orig.) : 28/09/2023 Rev.Date # 00
Process Step
Current Process Action Results

Severity

Class

Occurrence

Occurrence
Potential Failure Resp. & Target

RPN
Detection

Detection
Requirement Potential Effect (s) of Failure Potential Causes / of failure Recommended Action

Severity
Mode completion date

RPN
Controls Prevention Controls Detection Actions Taken & completion date

Function
Next Opn.-May be impact on tool life

Set-up approval, Inprocess

Over size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 4 Inspection & patrol 5 80
Inspection
End User-Nil
OD
(Ø39.20±0.10) Next Opn.-Part may reject/unclean

Set-up approval, Inprocess

Under size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 3 Inspection & patrol 5 60
Inspection
End User-Nil

Next Opn.-May be impact on tool life

Set-up approval, Inprocess

Over size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 4 Inspection & patrol 5 80
Inspection
End User-Nil
OD
(Ø42.80±0.10) Next Opn.-Part may reject/unclean

Set-up approval, Inprocess

Under size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 3 Inspection & patrol 5 60
Inspection
End User-Nil

Next Opn.-May be impact on tool life

Set-up approval, Inprocess

Over size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 4 Inspection & patrol 5 80
Inspection
End User-Nil
OD
(Ø48.90±0.10) Next Opn.-Part may reject/unclean

Set-up approval, Inprocess

Under size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 3 Inspection & patrol 5 60
Inspection
End User-Nil

Next Opn.-May be impact on tool life

Set-up approval, Inprocess

Over size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 4 Inspection & patrol 5 80
Inspection
End User-Nil
OD
(Ø63.90±0.10) Next Opn.-Part may reject/unclean

Set-up approval, Inprocess

Under size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 3 Inspection & patrol 5 60
Inspection
End User-Nil

Next Opn.-Nil

40 Programm monitoring by supervisor, Set-up approval, Inprocess

Radius Wrong insert, Programm disturbed
CNC Rough More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(R13.00±0.20)
Turning 2nd setup approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Radius Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(R0.80±0.10)
approval from qauality dept. Inspection
End User-Nil

Doc No. RPEW/F/QAD/13 Rev No. 00 Date 01/04/2021

 Page 5 of 23

RP Engineering Works

PROCESS FMEA
Item: Albero Shaft Process Responsibility: HOD (QA), HOD (Process Engg), HOD (Machining) FMEA Number RP-FMEA-ST-26

Part No. / Drg. No. 0.45950685or (Rev # h /(20/09/2023) Key Date: 28/09/2023 Prepared By: Mr.Ashutosh Yadav
40
CNC
Model Rough
Year(s) / Program - Core CFT Team: Nirdesh ,Sushil ,Om prakash. FMEA Date (Orig.) : 28/09/2023 Rev.Date # 00
Turning 2nd setup
Process Step
Current Process Action Results

Severity

Class

Occurrence

Occurrence
Potential Failure Resp. & Target

RPN
Detection

Detection
Requirement Potential Effect (s) of Failure Potential Causes / of failure Recommended Action

Severity
Mode completion date

RPN
Controls Prevention Controls Detection Actions Taken & completion date

Function
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Angle Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(45°±30')
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(163.00±0.20) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(60.00±0.20) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(43.25±0.10) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(43.00±0.10) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(21.50±0.10) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Chamfer Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(1.50X45°max )
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Chamfer Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(0.74±0.10X45°max )
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Angle Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(30°±30')
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Radius Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(R0.80~0.12)
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Spindle Outness Monitoring, Centre Set-up approval, Inprocess
Runout
More Customer Uses-Nil 4 Center Height disturbed, Spindle outness height adjustment and minitoring during 3 Inspection & patrol 5 60
(0.10)
setting Inspection
End User-Performance May Effect
Next Opn.-Nil
Spindle Outness Monitoring, Centre Set-up approval, Inprocess
Runout
More Customer Uses-Nil 4 Center Height disturbed, Spindle outness height adjustment and minitoring during 3 Inspection & patrol 5 60
(0.10)
setting Inspection
End User-Performance May Effect
Next Opn.-Nil
Spindle Outness Monitoring, Centre Set-up approval, Inprocess
Runout
More 4 Center Height disturbed, Spindle outness height adjustment and minitoring during 3 Inspection & patrol 5 60
(0.10)
setting Inspection

Doc No. RPEW/F/QAD/13 Rev No. 00 Date 01/04/2021

 Page 6 of 23

RP Engineering Works

PROCESS FMEA
Item: Albero Shaft Process Responsibility: HOD (QA), HOD (Process Engg), HOD (Machining) FMEA Number RP-FMEA-ST-26

Part No. / Drg. No. 0.45950685or (Rev # h /(20/09/2023) Key Date: 28/09/2023 Prepared By: Mr.Ashutosh Yadav

Model Year(s) / Program - Core CFT Team: Nirdesh ,Sushil ,Om prakash. FMEA Date (Orig.) : 28/09/2023 Rev.Date # 00
Process Step
Current Process Action Results

Severity

Class

Occurrence

Occurrence
Potential Failure Resp. & Target

RPN
Detection

Detection
Requirement Potential Effect (s) of Failure Potential Causes / of failure Recommended Action

Severity
Mode completion date

RPN
Controls Prevention Controls Detection Actions Taken & completion date

Function
Spindle Outness Monitoring, Centre Set-up approval, Inprocess
Runout
More Customer Uses-Nil 4 Center Height disturbed, Spindle outness height adjustment and minitoring during 3 Inspection & patrol 5 60
(0.10)
setting Inspection
End User-Performance May Effect
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(482.±0.20) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(2.32.±0.05) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Center Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(R4 x B.5Din332) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-May be impact on tool life

Set-up approval, Inprocess

Over size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 4 Inspection & patrol 5 80
Inspection
End User-Nil
OD
(Ø34.75-0.05) Next Opn.-Part may reject/unclean

Set-up approval, Inprocess

Under size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 3 Inspection & patrol 5 60
Inspection
End User-Nil

Next Opn.-May be impact on tool life

Set-up approval, Inprocess

Over size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 4 Inspection & patrol 5 80
Inspection
End User-Nil
OD
(Ø33.30-0.10) Next Opn.-Part may reject/unclean

Set-up approval, Inprocess

Under size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 3 Inspection & patrol 5 60
Inspection
End User-Nil

Doc No. RPEW/F/QAD/13 Rev No. 00 Date 01/04/2021

 Page 7 of 23

RP Engineering Works

PROCESS FMEA
Item: Albero Shaft Process Responsibility: HOD (QA), HOD (Process Engg), HOD (Machining) FMEA Number RP-FMEA-ST-26

Part No. / Drg. No. 0.45950685or (Rev # h /(20/09/2023) Key Date: 28/09/2023 Prepared By: Mr.Ashutosh Yadav

Model Year(s) / Program - Core CFT Team: Nirdesh ,Sushil ,Om prakash. FMEA Date (Orig.) : 28/09/2023 Rev.Date # 00
Process Step
Current Process Action Results

Severity

Class

Occurrence

Occurrence
Potential Failure Resp. & Target

RPN
Detection

Detection
Requirement Potential Effect (s) of Failure Potential Causes / of failure Recommended Action

Severity
Mode completion date

RPN
Controls Prevention Controls Detection Actions Taken & completion date

Function
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Radius Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(R2.00±0.10)
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Angle Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(30°±30')
approval from qauality dept. Inspection
End User-Nil
Next Opn.-May be impact on tool life

Set-up approval, Inprocess

Over size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 4 Inspection & patrol 5 80
Inspection
End User-Nil
OD
(Ø30.95-0.12) Next Opn.-Part may reject/unclean

Set-up approval, Inprocess

Under size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 3 Inspection & patrol 5 60
Inspection
End User-Nil

Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(2.56+0.04) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(2.56+0.04) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Radius Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(R0.20max)
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Radius Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(R0.20max)
approval from qauality dept. Inspection
End User-Nil

Doc No. RPEW/F/QAD/13 Rev No. 00 Date 01/04/2021

 Page 8 of 23

RP Engineering Works

PROCESS FMEA
Item: Albero Shaft Process Responsibility: HOD (QA), HOD (Process Engg), HOD (Machining) FMEA Number RP-FMEA-ST-26

Part No. / Drg. No. 0.45950685or (Rev # h /(20/09/2023) Key Date: 28/09/2023 Prepared By: Mr.Ashutosh Yadav

Model Year(s) / Program - Core CFT Team: Nirdesh ,Sushil ,Om prakash. FMEA Date (Orig.) : 28/09/2023 Rev.Date # 00
Process Step
Current Process Action Results

Severity

Class

Occurrence

Occurrence
Potential Failure Resp. & Target

RPN
Detection

Detection
Requirement Potential Effect (s) of Failure Potential Causes / of failure Recommended Action

Severity
Mode completion date

RPN
Controls Prevention Controls Detection Actions Taken & completion date

Function
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Radius Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(R0.20max)
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Radius Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(R1.50±0.10)
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(8.00±0.10) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Radius Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(R1.50±0.10)
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(3.50±0.05) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(2.80±0.05) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(18.00±0.05) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(16.30±0.05) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(27.90±0.05) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil

Doc No. RPEW/F/QAD/13 Rev No. 00 Date 01/04/2021

 Page 9 of 23

RP Engineering Works

PROCESS FMEA
Item: Albero Shaft Process Responsibility: HOD (QA), HOD (Process Engg), HOD (Machining) FMEA Number RP-FMEA-ST-26

Part No. / Drg. No. 0.45950685or (Rev # h /(20/09/2023) Key Date: 28/09/2023 Prepared By: Mr.Ashutosh Yadav

Model Year(s) / Program - Core CFT Team: Nirdesh ,Sushil ,Om prakash. FMEA Date (Orig.) : 28/09/2023 Rev.Date # 00
Process Step
Current Process Action Results

Severity

Class

Occurrence

Occurrence
Potential Failure Resp. & Target

RPN
Detection

Detection
Requirement Potential Effect (s) of Failure Potential Causes / of failure Recommended Action

Severity
Mode completion date

RPN
Controls Prevention Controls Detection Actions Taken & completion date

Function
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Radius Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(R0.40)
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(107.98±0.05) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(38.775-0.05) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(7.80±0.05) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Radius Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(R0.40)
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Chamfer Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(0.12~0.20X45°max )
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Chamfer Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(0.25~0.35X45°max )
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(0.20max) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil

Doc No. RPEW/F/QAD/13 Rev No. 00 Date 01/04/2021

50
CNC Finish Turning
 Page 10 of 23

RP Engineering Works

PROCESS FMEA
Item: Albero Shaft Process Responsibility: HOD (QA), HOD (Process Engg), HOD (Machining) FMEA Number RP-FMEA-ST-26

Part No. / Drg. No. 0.45950685or (Rev # h /(20/09/2023) Key Date: 28/09/2023 Prepared By: Mr.Ashutosh Yadav

Model Year(s) / Program - Core CFT Team: Nirdesh ,Sushil ,Om prakash. FMEA Date (Orig.) : 28/09/2023 Rev.Date # 00
Process Step
Current Process Action Results

Severity

Class

Occurrence

Occurrence
Potential Failure Resp. & Target

RPN
Detection

Detection
Requirement Potential Effect (s) of Failure Potential Causes / of failure Recommended Action

Severity
Mode completion date

RPN
Controls Prevention Controls Detection Actions Taken & completion date

Function
Next Opn.-May be impact on tool life

Set-up approval, Inprocess

Over size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 4 Inspection & patrol 5 80
Inspection
End User-Nil
OD
(Ø30min.) Next Opn.-Part may reject/unclean

Set-up approval, Inprocess

Under size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 3 Inspection & patrol 5 60
Inspection
End User-Nil

Next Opn.-May be impact on tool life

Set-up approval, Inprocess

Over size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 4 Inspection & patrol 5 80
Inspection
End User-Nil
OD
(Ø35.30-0.10) Next Opn.-Part may reject/unclean

Set-up approval, Inprocess

Under size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 3 Inspection & patrol 5 60
Inspection
50 End User-Nil
CNC Finish Turning
1st setup Next Opn.-May be impact on tool life

Set-up approval, Inprocess

Over size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 4 Inspection & patrol 5 80
Inspection
End User-Nil
OD
(Ø40.30-0.10) Next Opn.-Part may reject/unclean

Set-up approval, Inprocess

Under size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 3 Inspection & patrol 5 60
Inspection
End User-Nil

Next Opn.-May be impact on tool life

Set-up approval, Inprocess

Over size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 4 Inspection & patrol 5 80
Inspection
End User-Nil
OD
(Ø46.15-0.05) Next Opn.-Part may reject/unclean

Set-up approval, Inprocess

Under size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 3 Inspection & patrol 5 60
Inspection
End User-Nil

Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Chamfer Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(1.35~01.50X45°max )
approval from qauality dept. Inspection
End User-Nil

Doc No. RPEW/F/QAD/13 Rev No. 00 Date 01/04/2021

 Page 11 of 23

RP Engineering Works

PROCESS FMEA
Item: Albero Shaft Process Responsibility: HOD (QA), HOD (Process Engg), HOD (Machining) FMEA Number RP-FMEA-ST-26

Part No. / Drg. No. 0.45950685or (Rev # h /(20/09/2023) Key Date: 28/09/2023 Prepared By: Mr.Ashutosh Yadav

Model Year(s) / Program - Core CFT Team: Nirdesh ,Sushil ,Om prakash. FMEA Date (Orig.) : 28/09/2023 Rev.Date # 00
Process Step
Current Process Action Results

Severity

Class

Occurrence

Occurrence
Potential Failure Resp. & Target

RPN
Detection

Detection
Requirement Potential Effect (s) of Failure Potential Causes / of failure Recommended Action

Severity
Mode completion date

RPN
Controls Prevention Controls Detection Actions Taken & completion date

Function
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Radius Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(R0.50 )
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Radius Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(R0.50 )
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Angle Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(30°±30')
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Radius Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(R0.20max )
approval from qauality dept. Inspection
End User-Nil
Next Opn.-May be impact on tool life

Set-up approval, Inprocess

Over size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 4 Inspection & patrol 5 80
Inspection
End User-Nil
OD
(Ø43.40-0.12) Next Opn.-Part may reject/unclean

Set-up approval, Inprocess

Under size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 3 Inspection & patrol 5 60
Inspection
End User-Nil

Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Radius Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(R0.80max )
approval from qauality dept. Inspection
End User-Nil
Next Opn.-May be impact on tool life

Set-up approval, Inprocess

Over size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 4 Inspection & patrol 5 80
Inspection
End User-Nil
OD
(Ø39.62-0.06) Next Opn.-Part may reject/unclean

Set-up approval, Inprocess

Under size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 3 Inspection & patrol 5 60
Inspection
End User-Nil

Doc No. RPEW/F/QAD/13 Rev No. 00 Date 01/04/2021

 Page 12 of 23

RP Engineering Works

PROCESS FMEA
Item: Albero Shaft Process Responsibility: HOD (QA), HOD (Process Engg), HOD (Machining) FMEA Number RP-FMEA-ST-26

Part No. / Drg. No. 0.45950685or (Rev # h /(20/09/2023) Key Date: 28/09/2023 Prepared By: Mr.Ashutosh Yadav

Model Year(s) / Program - Core CFT Team: Nirdesh ,Sushil ,Om prakash. FMEA Date (Orig.) : 28/09/2023 Rev.Date # 00
Process Step
Current Process Action Results

Severity

Class

Occurrence

Occurrence
Potential Failure Resp. & Target

RPN
Detection

Detection
Requirement Potential Effect (s) of Failure Potential Causes / of failure Recommended Action

Severity
Mode completion date

RPN
Controls Prevention Controls Detection Actions Taken & completion date

Function
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Chamfer Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(1.00X30°max )
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Radius Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(R0.50)
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(3.92+0.20) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Chamfer Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
0.40±0.06X30°max )
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Angle Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(45°±30')
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Chamfer Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
0.40±0.06X30°max )
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(4.40±0.05) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(17.60±0.05) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil

Doc No. RPEW/F/QAD/13 Rev No. 00 Date 01/04/2021

 Page 13 of 23

RP Engineering Works

PROCESS FMEA
Item: Albero Shaft Process Responsibility: HOD (QA), HOD (Process Engg), HOD (Machining) FMEA Number RP-FMEA-ST-26

Part No. / Drg. No. 0.45950685or (Rev # h /(20/09/2023) Key Date: 28/09/2023 Prepared By: Mr.Ashutosh Yadav

Model Year(s) / Program - Core CFT Team: Nirdesh ,Sushil ,Om prakash. FMEA Date (Orig.) : 28/09/2023 Rev.Date # 00
Process Step
Current Process Action Results

Severity

Class

Occurrence

Occurrence
Potential Failure Resp. & Target

RPN
Detection

Detection
Requirement Potential Effect (s) of Failure Potential Causes / of failure Recommended Action

Severity
Mode completion date

RPN
Controls Prevention Controls Detection Actions Taken & completion date

Function
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Conncentricity Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(0.03)
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(20.90±0.05) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(85.05±0.05) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Conncentricity Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(0.05)
approval from qauality dept. Inspection
End User-Nil
Next Opn.-May be impact on tool life

Set-up approval, Inprocess

Over size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 4 Inspection & patrol 5 80
Inspection
End User-Nil
OD
(Ø63.00) Next Opn.-Part may reject/unclean

Set-up approval, Inprocess

Under size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 3 Inspection & patrol 5 60
Inspection
End User-Nil

Next Opn.-Nil
Insert Life & Speed & Feed Set-up approval, Inprocess
Surface Finish Insert wear , Speed & Feed not proper,
More Customer Uses-Nil 4 Monitoring, Coolant proper flow 3 Inspection & patrol 5 60
(Ra1.00) coolant flow not proper
toward tool Inspection
End User-Performance May Effect
Next Opn.-Nil
Insert Life & Speed & Feed Set-up approval, Inprocess
Surface Finish Insert wear , Speed & Feed not proper,
More Customer Uses-Nil 4 Monitoring, Coolant proper flow 3 Inspection & patrol 5 60
(Ra1.00) coolant flow not proper
toward tool Inspection
End User-Performance May Effect
Next Opn.-Nil
Insert Life & Speed & Feed Set-up approval, Inprocess
Surface Finish Insert wear , Speed & Feed not proper,
More Customer Uses-Nil 4 Monitoring, Coolant proper flow 3 Inspection & patrol 5 60
(Ra1.00) coolant flow not proper
toward tool Inspection
End User-Performance May Effect

Doc No. RPEW/F/QAD/13 Rev No. 00 Date 01/04/2021

 Page 14 of 23

RP Engineering Works

PROCESS FMEA
Item: Albero Shaft Process Responsibility: HOD (QA), HOD (Process Engg), HOD (Machining) FMEA Number RP-FMEA-ST-26

Part No. / Drg. No. 0.45950685or (Rev # h /(20/09/2023) Key Date: 28/09/2023 Prepared By: Mr.Ashutosh Yadav

Model Year(s) / Program - Core CFT Team: Nirdesh ,Sushil ,Om prakash. FMEA Date (Orig.) : 28/09/2023 Rev.Date # 00
Process Step
Current Process Action Results

Severity

Class

Occurrence

Occurrence
Potential Failure Resp. & Target

RPN
Detection

Detection
Requirement Potential Effect (s) of Failure Potential Causes / of failure Recommended Action

Severity
Mode completion date

RPN
Controls Prevention Controls Detection Actions Taken & completion date

Function
Next Opn.-Nil
Insert Life & Speed & Feed Set-up approval, Inprocess
Surface Finish Insert wear , Speed & Feed not proper,
More Customer Uses-Nil 4 Monitoring, Coolant proper flow 3 Inspection & patrol 5 60
(Ra1.00) coolant flow not proper
toward tool Inspection
End User-Performance May Effect
Next Opn.-Nil
Insert Life & Speed & Feed Set-up approval, Inprocess
Surface Finish Insert wear , Speed & Feed not proper,
More Customer Uses-Nil 4 Monitoring, Coolant proper flow 3 Inspection & patrol 5 60
(Ra1.00) coolant flow not proper
toward tool Inspection
End User-Performance May Effect
Next Opn.-Nil
Insert Life & Speed & Feed Set-up approval, Inprocess
Surface Finish Insert wear , Speed & Feed not proper,
More Customer Uses-Nil 4 Monitoring, Coolant proper flow 3 Inspection & patrol 5 60
(Ra1.00) coolant flow not proper
toward tool Inspection
End User-Performance May Effect
Next Opn.-Nil
Insert Life & Speed & Feed Set-up approval, Inprocess
Surface Finish Insert wear , Speed & Feed not proper,
More Customer Uses-Nil 4 Monitoring, Coolant proper flow 3 Inspection & patrol 5 60
(Ra1.00) coolant flow not proper
toward tool Inspection
End User-Performance May Effect
Next Opn.-Nil
Insert Life & Speed & Feed Set-up approval, Inprocess
Surface Finish Insert wear , Speed & Feed not proper,
More Customer Uses-Nil 4 Monitoring, Coolant proper flow 3 Inspection & patrol 5 60
(Ra3.00) coolant flow not proper
toward tool Inspection
End User-Performance May Effect

Doc No. RPEW/F/QAD/13 Rev No. 00 Date 01/04/2021

 Page 15 of 23

RP Engineering Works

PROCESS FMEA
Item: Albero Shaft Process Responsibility: HOD (QA), HOD (Process Engg), HOD (Machining) FMEA Number RP-FMEA-ST-26

Part No. / Drg. No. 0.45950685or (Rev # h /(20/09/2023) Key Date: 28/09/2023 Prepared By: Mr.Ashutosh Yadav

Model Year(s) / Program - Core CFT Team: Nirdesh ,Sushil ,Om prakash. FMEA Date (Orig.) : 28/09/2023 Rev.Date # 00
Process Step
Current Process Action Results

Severity

Class

Occurrence

Occurrence
Potential Failure Resp. & Target

RPN
Detection

Detection
Requirement Potential Effect (s) of Failure Potential Causes / of failure Recommended Action

Severity
Mode completion date

RPN
Controls Prevention Controls Detection Actions Taken & completion date

Function
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(478.60.-0.10) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(8.22±0.10) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
ID
(Ø12.50) Next Opn.-May be impact on tool life
Set-up approval, Inprocess
Under size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 4 Inspection & patrol 5 80
Inspection
60
CNC Finish Turning End User-Nil
2nd setup
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Angle Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(60°±30')
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil

Center dia Insert Life Monitoring , Part Set-up approval, Inprocess

Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(Æ16.30) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Chamfer Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(2.15 X45°max )
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Insert Life & Speed & Feed Set-up approval, Inprocess
Surface Finish Insert wear , Speed & Feed not proper,
More Customer Uses-Nil 4 Monitoring, Coolant proper flow 3 Inspection & patrol 5 60
(Ra3.00) coolant flow not proper
toward tool Inspection
End User-Performance May Effect
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(185.60±0.025) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(16.10±0.05) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(4.40±0.05) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Chamfer Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
0.40±0.06X30°max )
approval from qauality dept. Inspection

Doc No. RPEW/F/QAD/13 Rev No. 00 Date 01/04/2021

 Page 16 of 23

RP Engineering Works

PROCESS FMEA
Item: Albero Shaft Process Responsibility: HOD (QA), HOD (Process Engg), HOD (Machining) FMEA Number RP-FMEA-ST-26

Part No. / Drg. No. 0.45950685or (Rev # h /(20/09/2023) Key Date: 28/09/2023 Prepared By: Mr.Ashutosh Yadav

Model Year(s) / Program - Core CFT Team: Nirdesh ,Sushil ,Om prakash. FMEA Date (Orig.) : 28/09/2023 Rev.Date # 00
Process Step
Current Process Action Results

Severity

Class

Occurrence

Occurrence
Potential Failure Resp. & Target

RPN
Detection

Detection
Requirement Potential Effect (s) of Failure Potential Causes / of failure Recommended Action

Severity
Mode completion date

RPN
Controls Prevention Controls Detection Actions Taken & completion date
Programm monitoring by supervisor, Set-up approval, Inprocess
Chamfer Wrong insert, Programm disturbed
Function More/Less 5 Insert verification during change and 3 Inspection & patrol 5 75
0.40±0.06X30°max )
approval from qauality dept. Inspection
End User-Nil
Next Opn.-May be impact on tool life

Set-up approval, Inprocess

Over size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 4 Inspection & patrol 5 80
Inspection
End User-Nil
OD
(Ø39.62-0.06) Next Opn.-Part may reject/unclean

Set-up approval, Inprocess

Under size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 3 Inspection & patrol 5 60
Inspection
End User-Nil

Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Radius Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(R0.80max)
approval from qauality dept. Inspection
End User-Nil
Next Opn.-May be impact on tool life

Set-up approval, Inprocess

Over size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 4 Inspection & patrol 5 80
Inspection
End User-Nil
OD
(Ø46.15-0.05) Next Opn.-Part may reject/unclean

Set-up approval, Inprocess

Under size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 3 Inspection & patrol 5 60
Inspection
End User-Nil

Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Conncentricity Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(0.05)
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Insert Life & Speed & Feed Set-up approval, Inprocess
Surface Finish Insert wear , Speed & Feed not proper,
More Customer Uses-Nil 4 Monitoring, Coolant proper flow 3 Inspection & patrol 5 60
(Ra1.20) coolant flow not proper
toward tool Inspection
End User-Performance May Effect
Next Opn.-Nil
Insert Life & Speed & Feed Set-up approval, Inprocess
Surface Finish Insert wear , Speed & Feed not proper,
More Customer Uses-Nil 4 Monitoring, Coolant proper flow 3 Inspection & patrol 5 60
(Ra1.00) coolant flow not proper
toward tool Inspection
End User-Performance May Effect
Next Opn.-Nil
Insert Life & Speed & Feed Set-up approval, Inprocess
Surface Finish Insert wear , Speed & Feed not proper,
More Customer Uses-Nil 4 Monitoring, Coolant proper flow 3 Inspection & patrol 5 60
(1.00) coolant flow not proper
toward tool Inspection
End User-Performance May Effect
Next Opn.-May be impact on tool life

Set-up approval, Inprocess

Over size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 4 Inspection & patrol 5 80
Inspection
End User-Nil
OD
(Ø43.40-0.12) Next Opn.-Part may reject/unclean

Set-up approval, Inprocess

Under size 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 3 Inspection & patrol 5 60
Inspection
Doc No. RPEW/F/QAD/13 Rev No. 00 Date 01/04/2021
 Page 17 of 23

RP Engineering Works

PROCESS FMEA
Item: Albero Shaft Process Responsibility: HOD (QA), HOD (Process Engg), HOD (Machining) FMEA Number RP-FMEA-ST-26

Part No. / Drg. No. 0.45950685or (Rev # h /(20/09/2023) Key Date: 28/09/2023 Prepared By: Mr.Ashutosh Yadav

Model Year(s) / Program - Core CFT Team: Nirdesh ,Sushil ,Om prakash. FMEA Date (Orig.) : 28/09/2023 Rev.Date # 00
Process Step
Current Process Action Results

Severity

Class

Occurrence

Occurrence
Potential Failure Resp. & Target

RPN
Detection

Detection
Requirement Potential Effect (s) of Failure Potential Causes / of failure Recommended Action

Severity
Mode completion date

RPN
OD Controls Prevention Controls Detection Actions Taken & completion date
(Ø43.40-0.12)
Function
Set-up approval, Inprocess
Under size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 3 Inspection & patrol 5 60
Inspection
End User-Nil

Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(3.92+0.20) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Angle Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(45°±30')
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Radius Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(R0.20max)
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Angle Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(30°±30')
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(7.80±0.05) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-May be impact on tool life

Set-up approval, Inprocess

Over size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 4 Inspection & patrol 5 80
Inspection
End User-Nil
OD
(Ø40.30-0.10) Next Opn.-Part may reject/unclean

Set-up approval, Inprocess

Under size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 3 Inspection & patrol 5 60
Inspection
End User-Nil

Doc No. RPEW/F/QAD/13 Rev No. 00 Date 01/04/2021

 Page 18 of 23

RP Engineering Works

PROCESS FMEA
Item: Albero Shaft Process Responsibility: HOD (QA), HOD (Process Engg), HOD (Machining) FMEA Number RP-FMEA-ST-26

Part No. / Drg. No. 0.45950685or (Rev # h /(20/09/2023) Key Date: 28/09/2023 Prepared By: Mr.Ashutosh Yadav

Model Year(s) / Program - Core CFT Team: Nirdesh ,Sushil ,Om prakash. FMEA Date (Orig.) : 28/09/2023 Rev.Date # 00
Process Step
Current Process Action Results

Severity

Class

Occurrence

Occurrence
Potential Failure Resp. & Target

RPN
Detection

Detection
Requirement Potential Effect (s) of Failure Potential Causes / of failure Recommended Action

Severity
Mode completion date

RPN
Controls Prevention Controls Detection Actions Taken & completion date

Function
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Chamfer Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(1.35~1.50 )max )
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Angle Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(30°±30')
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Radius Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(R0.50)
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Angle Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(30°±30')
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(16.90) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(51.90±0.05) Wrong offset, Machine variation
PM, Scheduled PM Inspection
70
End User-Nil
CNC Finish Turning
3rd setup Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Radius Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(R0.40)
approval from qauality dept. Inspection
End User-Nil
Next Opn.-May be impact on tool life

Set-up approval, Inprocess

Over size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 4 Inspection & patrol 5 80
Inspection
End User-Nil
OD
(Ø34.80-0.10)

Doc No. RPEW/F/QAD/13 Rev No. 00 Date 01/04/2021

 Page 19 of 23

RP Engineering Works

70 PROCESS FMEA
CNC Finish Turning
Item: 3rd setup Albero Shaft Process Responsibility: HOD (QA), HOD (Process Engg), HOD (Machining) FMEA Number RP-FMEA-ST-26

Part No. / Drg. No. 0.45950685or (Rev # h /(20/09/2023) Key Date: 28/09/2023 Prepared By: Mr.Ashutosh Yadav

Model Year(s) / Program - Core CFT Team: Nirdesh ,Sushil ,Om prakash. FMEA Date (Orig.) : 28/09/2023 Rev.Date # 00
Process Step
Current Process Action Results

Severity

Class

Occurrence

Occurrence
Potential Failure Resp. & Target

RPN
Detection

Detection
Requirement Potential Effect (s) of Failure Potential Causes / of failure Recommended Action

Severity
Mode completion date

RPN
Controls Prevention Controls Detection Actions Taken & completion date

Function
OD
(Ø34.80-0.10) Next Opn.-Part may reject/unclean

Set-up approval, Inprocess

Under size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 3 Inspection & patrol 5 60
Inspection
End User-Nil

Next Opn.-May be impact on tool life

Set-up approval, Inprocess

Over size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 4 Inspection & patrol 5 80
Inspection
End User-Nil
OD
(Ø22.50) Next Opn.-Part may reject/unclean

Set-up approval, Inprocess

Under size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 3 Inspection & patrol 5 60
Inspection
End User-Nil

Next Opn.-May be impact on tool life

Set-up approval, Inprocess

Over size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 4 Inspection & patrol 5 80
Inspection
End User-Nil
OD
(Ø24.07-0.05) Next Opn.-Part may reject/unclean

Set-up approval, Inprocess

Under size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 3 Inspection & patrol 5 60
Inspection
End User-Nil

Next Opn.-May be impact on tool life

Set-up approval, Inprocess

Over size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 4 Inspection & patrol 5 80
Inspection
End User-Nil
OD
(Ø22.84-0.015) Next Opn.-Part may reject/unclean

Set-up approval, Inprocess

Under size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 3 Inspection & patrol 5 60
Inspection
End User-Nil

Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Radius Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(R13.00±0.20)
approval from qauality dept. Inspection
End User-Nil
Next Opn.-May be impact on tool life

Set-up approval, Inprocess

Over size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 4 Inspection & patrol 5 80
Inspection
End User-Nil
OD
(Ø36.78±0.010)

Doc No. RPEW/F/QAD/13 Rev No. 00 Date 01/04/2021

 Page 20 of 23

RP Engineering Works

PROCESS FMEA
Item: Albero Shaft Process Responsibility: HOD (QA), HOD (Process Engg), HOD (Machining) FMEA Number RP-FMEA-ST-26

Part No. / Drg. No. 0.45950685or (Rev # h /(20/09/2023) Key Date: 28/09/2023 Prepared By: Mr.Ashutosh Yadav

Model Year(s) / Program - Core CFT Team: Nirdesh ,Sushil ,Om prakash. FMEA Date (Orig.) : 28/09/2023 Rev.Date # 00
Process Step
Current Process Action Results

Severity

Class

Occurrence

Occurrence
Potential Failure Resp. & Target

RPN
Detection

Detection
Requirement Potential Effect (s) of Failure Potential Causes / of failure Recommended Action

Severity
Mode completion date

RPN
Controls Prevention Controls Detection Actions Taken & completion date

Function
OD
(Ø36.78±0.010) Next Opn.-Part may reject/unclean

Set-up approval, Inprocess

Under size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 3 Inspection & patrol 5 60
Inspection
End User-Nil

Next Opn.-Nil
Insert Life & Speed & Feed Set-up approval, Inprocess
Surface Finish Insert wear , Speed & Feed not proper,
More Customer Uses-Nil 4 Monitoring, Coolant proper flow 3 Inspection & patrol 5 60
(1.60~3.20) coolant flow not proper
toward tool Inspection
End User-Performance May Effect
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Conncentricity Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(0.02)
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(59.80) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(40.40±0.05) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Insert Life & Speed & Feed Set-up approval, Inprocess
Perpendicularity Insert wear , Speed & Feed not proper,
More Customer Uses-Nil 4 Monitoring, Coolant proper flow 3 Inspection & patrol 5 60
(0.010max) coolant flow not proper
toward tool Inspection
End User-Performance May Effect
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Angle Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(45°±30')
approval from qauality dept. Inspection
End User-Nil
Next Opn.-Nil
Insert Life & Speed & Feed Set-up approval, Inprocess
Surface Finish Insert wear , Speed & Feed not proper,
More Customer Uses-Nil 4 Monitoring, Coolant proper flow 3 Inspection & patrol 5 60
(1.60~3.20) coolant flow not proper
toward tool Inspection
End User-Performance May Effect
Next Opn.-Nil
Programm monitoring by supervisor, Set-up approval, Inprocess
Conncentricity Wrong insert, Programm disturbed
More/Less Customer Uses-Fitment May Effect 5 Insert verification during change and 3 Inspection & patrol 5 75
(0.02)
approval from qauality dept. Inspection
End User-Nil

Doc No. RPEW/F/QAD/13 Rev No. 00 Date 01/04/2021

 Page 21 of 23

RP Engineering Works

PROCESS FMEA
Item: Albero Shaft Process Responsibility: HOD (QA), HOD (Process Engg), HOD (Machining) FMEA Number RP-FMEA-ST-26

Part No. / Drg. No. 0.45950685or (Rev # h /(20/09/2023) Key Date: 28/09/2023 Prepared By: Mr.Ashutosh Yadav

Model Year(s) / Program - Core CFT Team: Nirdesh ,Sushil ,Om prakash. FMEA Date (Orig.) : 28/09/2023 Rev.Date # 00
Process Step
Current Process Action Results

Severity

Class

Occurrence

Occurrence
Potential Failure Resp. & Target

RPN
Detection

Detection
Requirement Potential Effect (s) of Failure Potential Causes / of failure Recommended Action

Severity
Mode completion date

RPN
Controls Prevention Controls Detection Actions Taken & completion date

Function
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(43.25-0.05) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(19.40) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(55.50) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(86.15±0.05) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Insert Life & Speed & Feed Set-up approval, Inprocess
Surface Finish Insert wear , Speed & Feed not proper,
More Customer Uses-Nil 4 Monitoring, Coolant proper flow 3 Inspection & patrol 5 60
(Ra1.00) coolant flow not proper
toward tool Inspection
End User-Performance May Effect
Next Opn.-Nil
Insert Life & Speed & Feed Set-up approval, Inprocess
Surface Finish Insert wear , Speed & Feed not proper,
More Customer Uses-Nil 4 Monitoring, Coolant proper flow 3 Inspection & patrol 5 60
(Ra1.00) coolant flow not proper
toward tool Inspection
End User-Performance May Effect
Next Opn.-Nil
Insert Life & Speed & Feed Set-up approval, Inprocess
Surface Finish Insert wear , Speed & Feed not proper,
More Customer Uses-Nil 4 Monitoring, Coolant proper flow 3 Inspection & patrol 5 60
(Ra3.20) coolant flow not proper
toward tool Inspection
End User-Performance May Effect
Next Opn.-May be impact on tool life

Set-up approval, Inprocess

Over size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 4 Inspection & patrol 5 80
Inspection
End User-Nil
OD
(Ø23.20-0.05) Next Opn.-Part may reject/unclean

Set-up approval, Inprocess

Under size Customer Uses-Nil 4 Tool Wear, Machine variation Tool Life Monitoring, PM as per plan 3 Inspection & patrol 5 60
Inspection
End User-Nil

80
VMC MILLING

Doc No. RPEW/F/QAD/13 Rev No. 00 Date 01/04/2021

 Page 22 of 23

RP Engineering Works

PROCESS FMEA
Item: Albero Shaft Process Responsibility: HOD (QA), HOD (Process Engg), HOD (Machining) FMEA Number RP-FMEA-ST-26

Part No. / Drg. No. 0.45950685or (Rev # h /(20/09/2023) Key Date: 28/09/2023 Prepared By: Mr.Ashutosh Yadav

Model Year(s) / Program - Core CFT Team: Nirdesh ,Sushil ,Om prakash. FMEA Date (Orig.) : 28/09/2023 Rev.Date # 00
Process Step
Current Process Action Results

Severity

Class

Occurrence

Occurrence
Potential Failure Resp. & Target

RPN
Detection

Detection
Requirement Potential Effect (s) of Failure Potential Causes / of failure Recommended Action

Severity
Mode completion date

RPN
Controls Prevention Controls Detection Actions Taken & completion date

Function
Next Opn.-Nil
80
VMC MILLING Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(6.40) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Insert Life Monitoring , Part Set-up approval, Inprocess
Dim. Insert wear, Coolant flow not proper,
More / Less Customer Uses-Fitment May Effect 5 verification after insert change, Daily 3 Inspection & patrol 5 75
(6.10) Wrong offset, Machine variation
PM, Scheduled PM Inspection
End User-Nil
Next Opn.-Nil
Insert Life & Speed & Feed Set-up approval, Inprocess
Surface Finish Insert wear , Speed & Feed not proper,
More Customer Uses-Nil 4 Monitoring, Coolant proper flow 3 Inspection & patrol 5 60
(Ra3.20) coolant flow not proper
toward tool Inspection
End User-Performance May Effect
Next Opn.-Nil

90 Folow up of Final Inspection

Identification Code Wrong Marking Customer Uses-Identification May Effect 5 No proper instruction 3 Setting Approval 6 90
Marking plan/marking insrtuction

End User-Nil

Next Opn.-Nil

100 Dimensional Customer Uses-May Reject at Identification & inspection

Not proper 5 No proper instruction Folow up of Final Inspection plan 3 7 105
Final Inspection Inspection Customer's end Status tag verification

End User-Nil

Next Opn.-Nil
110
Customer Uses-May Reject at
Pre Dispatch PDI Not proper 5 No proper instruction Folow up of PDI REPORT 2 PDI Report 6 60
Customer's end
Inspection
End User-Nil

Next Opn.-Nil

120 Material in good Customer Uses-May Effect in fitment &

Dent, rusty 4 No proper instruction Folow up of Packing Standard 2 Visual Inspection 7 56
Oiling & Packing condition bad visual

End User-Nil

Doc No. RPEW/F/QAD/13 Rev No. 00 Date 01/04/2021

 Page 23 of 23

RP Engineering Works

PROCESS FMEA
Item: Albero Shaft Process Responsibility: HOD (QA), HOD (Process Engg), HOD (Machining) FMEA Number RP-FMEA-ST-26

Part No. / Drg. No. 0.45950685or (Rev # h /(20/09/2023) Key Date: 28/09/2023 Prepared By: Mr.Ashutosh Yadav

Model Year(s) / Program - Core CFT Team: Nirdesh ,Sushil ,Om prakash. FMEA Date (Orig.) : 28/09/2023 Rev.Date # 00
Process Step
Current Process Action Results

Severity

Class

Occurrence

Occurrence
Potential Failure Resp. & Target

RPN
Detection

Detection
Requirement Potential Effect (s) of Failure Potential Causes / of failure Recommended Action

Severity
Mode completion date

RPN
Controls Prevention Controls Detection Actions Taken & completion date

Function
Next Opn.-Nil

130 OK qty. with good Wrong qty &

Customer Uses-Not received on Time 5 Identification Tag Not Clearly Visible Proper house keeping/tagging 2 Visual verification 7 70
Dispatch quality Defective Material

End User-Nil

Legends: or SC=Critical characteristics as per drawing ▶ = Critical characteristics as per process Important characteristics as per drawing
* Major characteristics as per process

Revision History

Rev. No Date Revision Details Revision Done By

H 20/09/2023 Æ34.75-0.05 was Æ34.80-0.10,Gr. Width 2.56+0.04 was 2.55+0.04 & Ch. 0.12~0.20x45°(3 Place ) added . Mr. Vinod

PREPARED BY : Mr Ashutosh Yadav APPROVED BY : Mr. Vinod Yadav

Doc No. RPEW/F/QAD/13 Rev No. 00 Date 01/04/2021