document.xlsx Printed 04:13:09,04/18/2023 Page 1 of 3

Failure modes and effects analysis (FMEA)

Project: QUAD TORC Date: 27/02/2015

FMEA Team: METAL HEADS -20150195 Prepared by: THOMAS J NEREVEETTIL

SEV = How severe is effect on the customer?

OCC = How frequent is the cause likely to occur?

DET = How probable is detection of cause?

RPN = Risk priority number in order to rank concerns; calculated as SEV x OCC x DET

Process step Potential failure mode Potential failure effects Potential causes Current process controls Actions taken

What is the step? 10 10 10 1000 10 10 10 1000

fuel empty tank 8 2 fuel gauge 4 64 1 1 1 1

fuel pump mechanical failure 8 improper maintanance of pump 5 none 8 320 2 2 3 12

battey corroded total electrical system failure 5 2 anti corrosion spray ,cleaning 2 20 proper maintainance maintainance done 1 1 1 1

starter motor mechanical failure cannot start the engine 7 3 maintainance 3 63 proper maintainance maintainance done 2 2 2 8

SEV

OCC

DET

RPN

Actions recommended

Responsibility (target date)

New SEV

New OCC

New DET

New RPN

In what ways can the step go wrong?

What is the impact on the customer if the failure mode is not prevented or corrected?

What causes the step to go wrong? (i.e., How could the failure mode occur?)

What are the existing controls that either prevent the failure mode from occurring or detect it should it occur?

What are the actions for reducing the occurrence of the cause or for improving its detection? You should provide actions on all high RPNs and on severity ratings of 9 or 10.

Who is responsible for the recommended action? What date should it be completed by?

What were the actions implemented? Include completion month/year (then recalculate resulting RPN).

unable to reach the destination / penality / time loss

fuel tank leak / unproper filling / low fuel efficiency / rong fuel gauge

proper filling / working fuel gauge

Thomas J N , ill be completed by 25/04/2015

working fuel gauge / stop the leakage

unable to reach the destination / penality / time loss

proper cleaning and maintainance of pump

Sen jacob John , will be completed by 26/04/2015

cleaned the pump and filteres

improper maintanance of battery and terminals

Kevin Eldho Issac ,will be completed by 25/04/2015

improper maintanance of motor / defetive

Sen jacob John , will be completed by 26/04/2015

document.xlsx Printed 04:13:09,04/18/2023 Page 2 of 3

Failure modes and effects analysis (FMEA)

Project: QUAD TORC Date: 27/02/2015

FMEA Team: METAL HEADS -20150195 Prepared by: THOMAS J NEREVEETTIL

SEV = How severe is effect on the customer?

OCC = How frequent is the cause likely to occur?

DET = How probable is detection of cause?

RPN = Risk priority number in order to rank concerns; calculated as SEV x OCC x DET

Process step Potential failure mode Potential failure effects Potential causes Current process controls Actions takenSEV

OCC

DET

RPN

Actions recommended

Responsibility (target date)

New SEV

New OCC

New DET

New RPN

switch fail to operate 7 1 ingnition switch 1 7 1 1 1 1

chassis bend / mechanical failure instability / danger to the driver 10 6 2 120 3 2 2 12

suspension 10 3 lotus suspension analysis 2 60 2 2 2 8

steering locking / mechanical failure instability /danger to Driver 8 3 testing and simuation 2 48 2 2 2 8

battey short circuit 9 inproper insulation / overloading 2 fuse / relay

3 54 1 1 1 1

fail to provide adequate power unable to start the engine and other electronic systems

manufacturiing defect / improper installation

replacement / maintainance

Thomas J N , will be completed by 27/04/2015

maintainance done / replaced

improper welding / material /design

impact testing / simulation and analysis

proper designing and testing

Thomas J N , will be completed by 27/04/2015

tested the design ,simulated and analyzed the problem ,made necessary changes

broken / unepected damping / mechanical failure

instability / danger to the driver / uncomfortable

improper designing and installation / wrong suspenson

proper designing and testing

Nikhil C Nandhan , will be completed by 27/04/2015

tested the design ,simulated and analyzed the problem ,made necessary changes

improper designing and installation

proper designing and testing

Toby Tony , will be completed by 28/04/2015

tested the design ,simulated and analyzed the problem ,made necessary changes

fire / total electrical system failure

proper insulation with right rated fuse / reduce overloading

Abhay , should be completed by 20/03/2015

proper insulaton was given , rated fuses were installed