Process Function /

No. Potential Failure Mode Potential Effects(s) S

Requirements
e
v

3
Tank preparation Broken screw bolt on tank Tank cannot be used, need to
rework a new tank

tank painting not meet the
impact the manufacture
6
Tank preparation requirements scarathes and damage
hours , delay in prodcution

Grinding process
Grinding wheel of right Grinding wheel of right material material cannot be used
right size wheel size wrongly used mating problem with next process




Potential Cause(s) / Mechanism(s) of O
c Current Process Controls Prevention
Failure
c
u
r

Unqualified welding Earlier tank preparation, if find out
problem we have enough time to
rework a new tank

1)
2) 1)
3) 2)
1) try to avoid the knocks and scratches
1) the tank is not properly fixed caused by bad operations
during transportation 2) ask the supplier to strengthen the
2) the improper operation during inspection
product assemblylead to collision
broken
3) do willing area to be painted (for Normal packing of tanks
example, the root of the shaft).

visual displayin stores not correct Visual display in stores

wheel spec not provided by design
operator training missing
PFMEA To



D
Current Process Controls Detection e Recommended Action(s)
t R
e P
c N
t
1)
2)
1) the supplier shall strengthen the inspection, and
Problem found during tank preparation each welding bolt shall be tested
2) increase the inspection item in the report and
show the result of the inspection

1)

2)
3)

4)

materials delivery inspection ,self check 1) strengthen the tank fixing during transportation
and storage check -- Inspection and avoid the crash caused by the friction between
before and after trasportation the tank
2) strengthen the inspection before the tank
dispatch
3) avoid the crash or scratch caused by the tools
on the tank
4) avoid the painting drop off during the tank lifted
due to improper loading tool

inspection at every 2 Hours Poke yoke, full proofing or detection to be made stronger


/
improvement
Evaluation after

Responsibility &

Target
Actions Taken
Completion O
D
Date S c
e c e
t R
v u P
r e
c N

1)


2)

3)
1) the supplier has made improvements for tank,
use the spring to fix the cover and the case, and
the supports have been increased to avoid the
crash between two tanks
2) improve the use of the ring during the tank lifting
process, and rotate the rings to the top of the tank
to avoid the friction during hanging ring
3) the metal tools are not directly placed on the
product during production

made stronger
 DEPARTMENT Final Assembly & Processing

No. Process Function / Requirements Potential Failure Mode

Inspection Window Not Matching

1 Tank Preparation
Properly with Tank Body

Bushing Flange Not matching with

2 Tank Preparation Turret Flange (All studs are not
matching)

Bushing Flange Not matching with

3 Tank Preparation Turret Flange (All studs are not
matching)

4 Tank Preparation Turret Not Matching with Tank Body

 CT Studs not matching in the turret
5 Turret Preparation
flange holes inside the turret

Turret Flange found without CT stud

6 Turret Preparation fixing Boss with tapped holes or
tapped holes on the flange

All holes of Turret Top Flange not

7 Turret Preparation
matching with the Bottom Part

8 CT assembly Improper CT assembly

9 CT assembly Improper CT assembly


PFMEA



Potential Cause(s) / Mechanism(s) O
Potential Effects(s) S c
of Failure
e c
v u
r

1. Unqualified
Tapping(Improper/Slant Tapping)
Leakage from Joints
2. Improper Drilling

1. Unqualified
Tapping(Improper/Slant Tapping)
Leakage from Joints
2. Improper Drilling

1. Unqualified
Tapping(Improper/Slant Tapping)
Bushing flange may brake
while foreceful matching
2. Improper Drilling
and tightening

1. Unqualified
Tapping(Improper/Slant Tapping)

2. Improper Drilling

3. Wrong hole to hole distance

Leakage from Joints ( Gap
marked for drilling
between Turret and Tank)
4. Error in Drawing

5. Drawing study not done properly

 1. Unqualified Tapping in welded
Boss(Improper/Slant Tapping)

Improper tightening of CT 2. Tapered welding of Tapped Boss

assembly
3. Paint inside the tapped Holes

1. Drwaing study not done properly

Unable to do the CT
assembly work 2. Revision in drawing and not
informed to supplier

1.Wrong hole to hole distance

marked for drilling
Leakage from Joint
2. Error in the drawing

3. Drawing study not done properly

Wrong Polarity during 1. Drawing Study not done Properly

Testing
2.

Wrong Polarity during

Testing
PFMEA(PROCESS FAILURE MODE E




Current Process Controls Current Process Controls D
Prevention Detection e
t R
e P
c N
t

Rework to be done on Tapped holes

Problem found during Tank
or Inspection cover hole size need
Preparation
to be increased

Wrong Hole need to be closed by Problem Found during Tank

welding & new hole to be made with Preparation, Tanking of the
new tapping Transformer & Bushing Fixing

Wrong Hole need to be closed by Problem Found during Tank

welding & new hole to be made with Preparation, Tanking of the
new tapping Transformer & Bushing Fixing

Rework to be done on Tapped holes Problem found during Turret

or the hole size of the matching assembly on Top tank (Tank
componenet need to be increased Preparation)
1. Retapping need to be done
2. Tapped Boss ned to be removed
and welded again in straight
condition
1. Problem Found During CT
assembly in tank preparation stage.
2. Problem Found During CT
assembly in tank preparation stage.

3. Retapping need to be done to 3. Problem Found During CT

remove the paint assembly in tank preparation stage.

Rework to be done on turret flange

Problem found during turret
and new boss to be welded in
Preparation/CT assembly stage.
factory which wastes a lot of time

The hole size of the matching

componenet need to be increased
in case of small mismatch and in Problem found during turret
case of big mismatch new turret preparation
flange need to be procured from
supplier
DE EFFECT ANALYSIS)
/

Responsibility
Recommended Action(s) & Target Actions Taken
Completion
Date


improvement
Evaluation after




O
D
S c
e c e
t R
v u P
r e
c N