Page 188 - DMGT524_TOTAL_QUALITY_MANAGEMENT

Unit 12: Failure Mode and Effect Analysis

The main parts which are produced in this industry are: Exhaust Manifold, Flywheel, Notes
Cylinder Block, Brake Discs, Portal Cover, Side Cover, Seal Carrier, Combined Pulleys
and Door Closures, etc. It supplies these tractors parts to the reputed tractor industries of
India. Various machines used in this industry are: Shell Core Making Machine, Shell Core
Shooter, Molding Machine, Sand Mixture Machine, Drilling Machine, Grinder and Slotting
Machine, etc.
FMEA technique is applied to two products, which are analyzed on the basis of their
manufacturing operations and design as discussed in the following section.
1. Flywheel Housing
2. Flywheel

Flywheel Housing
Facing, drilling and tapping are the main manufacturing operations of the Flywheel
Housing. Firstly, the basic requirements of the manufacturing processes are studied and
then the potential failure mode of the specific process is found out. After that the potential
effects of the failure mode are noted with their severity value. The occurrence value for the
potential causes and their prevention is also calculated. The Detection value is assigned to
the failure mode and finally the R.P.N. value is calculated. The sample calculations are
given in the following section.
Sample Calculations
Step 1: Potential Failure Modes for Facing, Drilling and Tapping are found.

Step 2: Potential Effect of Failure and Severity value are calculated as:
Part may fail in field/Assembly & Customer dissatisfaction and corresponding
Severity value = 7
Step 3: Potential causes of failure & occurrence value for Facing, Drilling and Tapping
are calculated as: For defective machine tool setting and corresponding Occurrence
value = 3

Step 4: For 100% in-process inspection and corresponding Detection value = 4
Step 5: Finally, the R.P.N. is calculated as:
R.P.N. = S × O × D
Considering S = 7, O = 3 and D = 4

The R.P.N. = 7 × 3 × 4 = 84
Flywheel
Following manufacturing operations are carried out on the Flywheel:
1. Turning on front side
2. Turning on back side

3. Drilling and Tapping
4. Balancing
After the study of the basic requirements of the manufacturing processes, the potential
failure mode of the specific process is found out. The potential effects of the failure mode
are required to be noted with their severity value. The potential causes and their prevention
are decided along with their occurrence value.
Contd...

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