improvements points to reduce the filling overfill

7/31/2019 Improvements Points to Reduce the Filling Overfill

1/20

Lower Upper

1 125

Move the X to

Control Plan and

record existing

controls for X

126 300

Take immediate

action on X to

reduce RPN to less

than 125

301 1000

Take X for Graphical

and Statistical

Analysis

Note:

Process or Product

Name:

Responsible:

Oil receipt

Incoming tanker at

BA'sMoisture analysis

Fails in Misture

analysis test

Product fails in

maintaining the

specific gravity

1

Oil receipt

Incoming tanker at

BA'sForeign Material Mixup with oil

Oil getscontaminated &

affect the filling

process

3

Oil receipt

Oil availability in

Day tank

level of oil in the

day tankOil empty out

Air entrapment and

under fillung of

bottles

9

Oil receipt

Service tank Service tank input

valve Valve not opened

People forgotten

to open

3

Oil receipt

Service tank Service tank input

valve Valve not opened

People forgotten

to open

1

Oil receiptService tank

Service tank Air entrapment Float valve jamme3

Filling machine Piston cylinder ML Bed rod

Improper weight

setting

Improper

tightment of

center nut

9

Process Function InputCharacteristic of

Input (KPIV / X)

Potential Failure

Mode (How the X

fails?)

Potential Effects

of Failure (Y or Mini-

Y)

S

E

V

RPN Rating ScaleAction to be taken

The above cut-off values are used as a thumbrule. Should you

want to use different cut-offs, please change the above values


2/20


Improper weight

setting

Improper

tightment of

center nut

1


Improper weight

setting

Improper

tightment of

center nut

9


Improper weight

setting

Weight

adjustment rod3


Improper weight

setting

Weight

adjustment rod

3


Improper weight

setting

Weight

adjustment rod

3

Filling machine Piston cylinder Piston

Deforming the

shape Over loaded

3

Filling machine Piston cylinder Piston

Deforming the

shape Over loaded3

Filling machine Piston cylinder NRV

Sediments

avaibility

Improper cleaning

of the tank

3

Filling machine Piston cylinder NRV

Sediments

avaibility

Improper cleaning

of the tank

1

Filling machine Piston cylinder Teflon washer Weight variation Air entrapment3

Filling machine Piston cylinder Teflon washer Weight variation Air entrapment1

Filling machine Front nozzle NRV

Sediments

avaibility

Improper cleaning

of the tank

3

Filling machine Front nozzle NRV

Sediments

avaibility

Improper cleaning

of the tank

1

Filling machine Front nozzle Spring Lose of elasticity Life time exceeds

3


3/20

Filling machine Front nozzle Oil dripping Spring damaaged Life time exceeds

3

Filling machine Front nozzle Oil dripping

Nozzle tip

damaged

Improper

handling

3

Filling machine Front nozzle Oil dripping

Nozzle tip

damaged

Improper

handling3

Filling machine

tare weight seting

in the weighing

balance

Improper setting

the nozzle Oil under filled Tare weight issues

9

Filling machine

tare weight seting

in the weighing

balance

Improper setting

the nozzle Oil over filled Tare weight issues

9

Filling machine

Electricity VoltageFluxuation in the

voltage

Damage the

sensitive parts of

the machine

9

Filling machine

Operator Skill Skillless operation Defect or Machinedamage

9

Filling machine

electricity VoltageFluxuation in the

voltage

Damage the

sensitive parts of

the machine

3

Filling machineInspector Skill Skillless operation

Defect or Machine

damage9

Bottle Weighment Weigh Balance Accuracy

Lower or

Highercapacity than

required

Impropper result of

weight9

Bottle Weighment Weigh Balance CapacityLower accuracy

than required

Impropper result of

weight

9

Bottle Weighment Weigh BalanceZero setting not

proper

Not covered

properly

Tare weight will not

correct & it affects

the net weight of

the bottle

9


4/20

Bottle Weighment Weigh BalanceZero setting not

properNot calibrated

Tare weight will not

correct & it affects

the net weight of

the bottle

3

Bottle Weighment Tare weight Empty bottle weightBottle above /

below specifications

Will affect the

weight in FG stage 4

Bottle WeighmentBottle weight

Identifications

Actual bottle weight

identifications

Wrong weight

identifications

Improper net

weight calculations

due to wrong tare

weight

9


IdentificationsFilled bottle weight

Note the filled

weight

Wrongly recording /

Not readable9


Identifications

Calculation of net

weightWrong calculation

Wrong recording of

the net weight9


5/20

Prepared by: Page ____ of ____

FMEA Date (Orig)

______________

(Rev)

_____________

Water mixup on the

oil3

Incoming oil

inspection of

moisture analysis

test -SOP

1 3

Improper cleaningof the tank / Not

closed the tanker

properly

3

Incoming oilinspection for

foreign Material -

SOP

3 27

Minimum stock

level not

maintained

9 no control 9 729

auto feedback loop

for low and high

pump start up and

stoppage to be

im limented

Unskilled

manpower

3

Trained person to

take the

ownership

3 27

1Checklist for startup

of the filling1 1

Filter bag not tied

properly3

Transparent Sheet

provided3 27

Thread damaged

in the nut

9MSL is not

maintained in PAC6 486

Critical spares list

maintained

Potential Cause(s)/

Mechanism(s) of

Failure (Sub X's)

O

C

C

Current

Process

Controls

D

E

T

R

P

N

Recommended

Action(s)

Process / Productailure Modes and Effects Analysis

(FMEA)


6/20

Bush worn out

3 PAC 6 18Critical spares list

maintained

Unskilled

manpower

9

skill building needs

to be performed to

build multipleauthority for weight

setting

2 162

Operator

trained before

put in Job

authority andmistake proffing

for SKU wise

setting to be

done

Thread Worn out6 PAC 1 18

Frequent

adjustment of the

rod

9Operator trained

before put in Job1 27

Adjustment donewithout loosing

the center nut

6 Operator trainedbefore put in Job

1 18

Improper

handling while

adjusting the

weight

3Operator trained


Cylinder sleeve

jamme3 PAC 3 27

Non adhering the

cleaning schedule

3Operator trained

before put in Job

1 9

Filter cloth

damaged

1 PAC 1 1

Improper fitting3

Operator trained


Damaged in the

washer3

Maintaining the

spares3 9

Non adhering the

cleaning schedule

3Operator trained


Filter cloth

damaged

1 PAC 1 1

Not determining

the life time

6

Frequency of

changing system to

be implemented

9 162

frequency to be

foud out using the

mechanical engg

hand book, after

spring type and

s ecifications


7/20

Not determining

the life time

6

Frequency of

changing system to

be implemented

9 162

frequency to be

foud out using the

mechanical engg

hand book, after

spring type and

s ecifications

Unskilled persons

3Operator trained

before put in Job

3 27

Frequent chnge

over6

Weight setting

design to be

modified

9 162

match making for

SKU change has to

be put in place

10 botle are

checked for

averaging the tare

waight to be

adjusted in the

weighing machine

4

every lot change

this activity I

performed

3 108

10 botle are

checked for

averaging the tare

waight to be

adjusted in the

weighing machine

4

every lot change

this activity I

performed

3 108

Electrical

consumption

variation between

machines

3

Stabiliser available

to reduce the

electrical noise

3 81

Inadequate trainingor less experience

1 Operator trainedbefore put in Job

9 81

3 1 9

Inadequate training 3Operator trained


Less awareness in

selection of

wighbalance

3Technical guidance

from ML given3 81

Less awareness in

selection of

wighbalance

3Technical guidance

from ML given

3 81

Disturbances by air

/ External forces /

Unlevelled machine

4

Weighing balnce

covered &

calibrated daily

2 72


8/20

Disturbances by air

/ External forces /

Unlevelled machine

6

Weighing balnce

covered &

calibrated daily

6 108

Change in the

weight during theblowing process

4

On - line checking at

blowing locations &

weight checking at

incoming PM stage

4 64

skill building not

done9 no control 6 486

Training provided to

the operator with

scheduled check

audits

skill building not


Training provided to

the operator with

scheduled check

audits

skill building not


Training provided tothe operator with

scheduled check

audits


9/20

Action Results S E V O C C

Actions Taken S E V O C C

Sabar and Ganesh 10.11.11 9


Responsibility Completion Date


10/20


ganesh 15.11.11 3


11/20

ganesh 15.11.11 3



12/20

ganesh 15.11.11 9

ganesh 15.11.11 9

ganesh 15.11.11 9


13/20

D E T R P N

D E T R P N

0

0


14/20

0

0


15/20

0

0


16/20

0

0

0


17/20

Sl No X Description of the X

1

level of oil in the day tank Oil empty out

2

pistion cylinder setting of ML Bed rod

thread damaged Improper weight setting

3 Improper Fill weight setting Improper weight setting

4 Cylinder size Higher cylinder size leads to overfill

5 Nozzle Spring Loss of elasticity

6 Oil dripping from nozzle Spring damaaged

7 Oil dripping from nozzle Nozzle tip damaged

8

Bottle weight checking Wrong weight identifications

9Filled bottle weight Weight recording structure

10Calculation of net weight Wrong calculation

Improve the Filling Machine Setting


18/20

Actions to be performed

auto feedback loop for low and high pump

start up and stoppage to be implemented

Critical spares list maintained

Develop SOP for the Fill weight setting.

Use the New Jig & Fixture (Provided to

SME) for setting fill weight accurately

Make the Fill volume matches the Cylinder

volume

Use of spring steel for nozzle return spring

Use of spring steel for nozzle return spring

Maintain necessary spare nozzle

Training provided to the operator with

scheduled check audits






19/20

Process Input Characteristic of Potential Failure Potential Eff

Set zero on theweighing m/c

weighing m/c calibrated m/czero setting notproper hencechange in bias

tare weight wicorrect & samchange net wfilled

Set zero on theweighing m/c weighing m/c Leveled

level setting notproper hencechange in bias

tare weight wicorrect & samchange net wfilled

Weight theempty bottles

Tare weight Empty bottleweight

Bottle below/abovespecification

will effect thethe FG stage

Write the tareweight of bottle

on the bottlesusing

temporarymarker

bottle weightidentification

actual bottle weightidentification

wrong identification/not readable

improper netcalculation duwrong tare w

Weight theFilled bottles Operator note filled weight

wrong recording/not readable

improper netcalculation du

wrong tare wWriting of Net

Weights onWeight Page

Operator Calculation of Netweight wrong calculation wrong typing

MAN

Improper setting ofm/c

Improper trainingwrong adjustmentpractice

Higher time tomachine henkeeping weighigher side

MACHINENozzle Dripping

Nozzle pipe enddamage

weight variationdue to extra oildripping from

higher/ lowerfilled.

MACHINE

Nozzle Dripping

Hose connectionloose near NRV

weight variationdue to extra oil

dripping from

higher/ lowerfilled.


20/20

ects S E VPotential Cause(s)/O C CCurrent D E T R P Nill not bee willeighjt

9disturbance by air/external forces/unlevelled machine

3weigh balance covered& calibrated every day

3 81

ill not bee willeighjt 6

disturbance externalforces/ unlevelledmachine

3weigh balance covered& calibrated every day 3

54

weight in 9changes in theweight duringblowing proces

9

online check at blowing

location & weight checkat incoming stage at PMreciept

7 567

eighte toight

7 improper writing 3 trainign provided to theoperator

5 105

eighte to

ight

7 improper writing 3trainign provided to theoperator 5

105

of the fig 7 improper keying ofthe fig. 3trainign provided to theoperator 5

105

sete

ht on the9

wrong practice ofweigt setting &change in themachine weightadjustment blocksetting.

9 training of the operator 9 729

weight6

crack in the nozzleend

3checked in case of anydripping oberved duringfilling

5 90

weight 6 Loosening of thehose due tocontinous movement

2 checked in case of anydripping oberved duringfilling

5 60

improvements points to reduce the filling overfill

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