Programme · PRG-2247
Brake Caliper Housing
TOYOTETSU INDIA AUTO PARTS (P) LTD · Part BRK-2247-A · PPAP Level 3 · FMEA — Risk priority numbers
Launch
2025-09-15
0 days to go
Status
AMBERPFMEA — Risk Items
| Step | Failure Mode | S | O | D | RPN | Action | Status |
|---|---|---|---|---|---|---|---|
| Casting | Porosity in housing wall | 9 | 4 | 3 | 108 | Add vacuum casting validation step | Open |
| Machining | Bore diameter out of tolerance | 8 | 3 | 2 | 48 | SPC chart on bore diameter — hourly check | Closed |
| Heat Treatment | Incorrect hardness | 9 | 2 | 4 | 72 | 100% hardness check post heat treatment | Open |
| Assembly | Seal groove damage | 7 | 3 | 3 | 63 | Visual inspection fixture at assembly station | Open |
| Pressure Test | Leak at seal interface | 10 | 2 | 2 | 40 | 100% pressure test at 150 bar | Closed |
| Casting | Flash / Burr formation | 5 | 5 | 2 | 50 | Die maintenance schedule — 500 shots | Open |