Process Risk Assessment - Revised

RISK ASSESSMENT FOR OFFSET
Requirements
Process Step : Description Function Potential Failure Mode
Product Process
Damages - During Transit /

Stores Material Receiving Material Receiving No Physical Damage No composition changes in RM Handling/ Environment
No Physical Damage Ink Lid open condition
GSM Less than PO / more than

Inspection Material Quality Inspection Correct GSM No changes in Board GSM PO
Correct Shade No shade variation in Board
Correct Size(Board) No Size variation in Board Size less then PO
stock not available as per job

Material Issue Issue the material to production Correct quantity As per MRN requirement
No material changes (As per

Correct Material wrong material issued
MRN)
Cutting Cut the paper to the size Correct size Size mentioned As per Job card Uneven size
Without dust Dots found in printing
Sharp Knife Dust found

Printing pass 1 To printing graphics & data 2 color Colour as per spec Color darker then sample
Color lighter then sample
No dust mark White dots found
No smudging Color variation
Ink not drying on time
Color variation
Ink as per Spec
Plate with correct color Font missing

seperation
Wrong plate sellection
Printing Pass 2 To printing graphics & data 2 color Colour as per spec Color darker then sample
Color lighter then sample
No dust mark White dots found
Color variation
Ink as per Spec
Plate with correct color Font missing

seperation
Wrong plate sellection
Curing To dry the Ink No Set of Ink not drying on time
Atmospeheric Temperature and Setof founded
Relative Humidity
Coating to seal the image No Ink transfer Setof
Color fadout
Matte finish done instead of

Correct Finish(matte/gloss) Glass
Glass finish done instead of
Matte
Viscocity time more

viscosity
Un even pressure
Roller pressure
Punching To cut the tag in desire shape Without bur Knife without sharp
Cross cutting
Even pressure,
Cross cutting
Sharp blade
Sorting Sort the product report wise No Mixup Variables mixing
Packing Pack the product as per report No shortage, Short Quantity,
Wrong packing details enclosed

Correct Report
Quantity less then packing
Final Inspection Inspect the Quantity and Quality Correct quantity report
Correct Quality Color shade diferent

Barcode reading Grade fail
Correct Product Finishing size less then actuval
Quantity not matching customer

Correct report PO
Dispatch Ship the goods Good cotton box Cotton box easily damage
Correct courier mode Delay in delivery to customer
On time booking Delay in delivery to customer
Correct documents Wrong Invoice enclosed
Instrument Calibration To get the accurate value accuracy

Incorect Output with wrong
Correct Output values
Chemicals Afect the Customer value Hazards
Customer Complaints Unknown the Hazards
Foreign Body Contamination Afect the Customer value injury

Customer Complaints Product Quality afects
Afect the End User & Customer injury

injury
Microbiological Contamination Afects the Product Health Product Quality & Productivity
Customer Complaints afects
R OFFSET PRINTSHOP
Current Process Controls
R.P.N.
Class
Det
Sev
Potential Efect(s) of Failure Potential Cause(s) of Failure,
Controls Controls
Occ
Prevention Detection
Packing standard, Approved
Unsuitable Packaging &
Commitment Failure 2 Logistics facility will be planned 1 Visual checking 2 212
Unapproved Logistics properly
Commitment Failure & it Sealed packing with good quality
may cause the product 1 Unsuitable Packaging containers used for ink and 2 Visual checking 3 123
changes chemical packing
Afect the Product Quality 1 Supplier wrongly selection Supplier adhere to follow the P.O 2 GSM Tester 2 122
Supplier adhere to follow the

Afect the Product Quality 2 Supplier wrongly selection 2 2 222
same Lot Number delivery
Supplier adhere to follow the P.O
Afect the Product Quality 1 Supplier wrongly selection & Using the Calibrated scale for 2 Scale 2 122
measurement
Excess quantity afect the Weighing & Counting system will Stock Count will be planned for weekly
1 Count control not efective 2 3 123
Customer Products count. be implemented basis.
Periodic review of efectiveness of

Commitment Failure 2 Un trained Employee Provide training for employee 2 2 222
training
Afect the Product Quality & 1 Zero setting failure Periodic calibration of zero setting 2 Random inspection of cut sheet 3 123
Size
Add to vaccum or blower in

Afect the Product Quality 2 Knife is blunt 2 Random inspection knife sharp 2 222
cutting machine
Add to vaccum or blower in

Afect the Product Quality 1 Knife is blunt 1 Knife should be changed in periodically 2 112
cutting machine
Approved sample enclosed with job
Rejection 2 incorrect Ink mixed color ratio 1 2 212
card for color ref
Rejection 2 incorrect Ink mixed color ratio 1 2 212
card for color ref
Segregation 1 Dust mixed to Ink 1 Planned Maintanance monthly once 2 112
Rejection 2 Wrong ink selected 2 Random inspection from supervisor 1 221
Rejection 2 Old stock selected 1 Random inspection from supervisor 2 212
Random inspection from supervisor

Rejection 2 Wrong ink selection 2 1 221
and Online QC
Setof 2 Old stock selection 1 1 213
and Online QC
Rejection 2 Not available font 1 Manual checking 1 211
Rejection 2 Operator carelesness Provide training for employee 1 Manual checking 2 212
Rejection 2 in correct Ink mixed color ratio 1 2 212
card for color ref
Rejection 2 in correct Ink mixed color ratio 1 2 212
card for color ref
Segrigation 1 Dust mixed to Ink 1 Planned Maintanance monthly once 2 112

Rejection 2 Wrong ink selection 1 1 221
and Online QC
Setof 2 Old stock selection 1 1 212
and Online QC
Rejection 2 Not available font 1 Manual checking 1 211
Rejection 2 Operator carelesness Provide training for employee 1 Manual checking 1 212
Set of 2 Driying delay 1 Control the machine speed 2 212
Rejection 2 Machine Hi Speed 1 Control the machine speed 2 212
have the instruction check list with job

Rejection 2 Curing time not followed 1 2 212
card
have the instruction check list with job
Rework 2 Without coating 2 2 222
card
Visual checking with jabcard And spec/
Rejection 2 Wrong information 1 1 211
sample.
Visual checking with jabcard And spec/
Rejection 2 Wrong information 1 2 212
sample.
Random checking and change the
Patches found 2 Quick drying the Coating 1 2 212
fresh coating
Random checking and correct the
Patches found 1 Not proper ink apply 1 2 112
roller balance
Rejection 1 Machine setting 1 Random Indspection 2 112
Rejection 1 Zero setting failure Periadic calibration of zero setting 1 Random inspection of cut sheet 2 112
Rejection 1 Zero setting failure Periadic calibration of zero setting 1 Random inspection of cut sheet 1 111
Rework 2 Sorting error 1 Random inspection of mixup 2 212
Commitment fail 2 counting mistake 1 2 212
Wrongly enter the qty from Visual checking with jobcard And spec/
Quantity diferent 2 1 1 211
Order entry sample.
Rejected sum quantity
Rework 2 Improve the online QC 1 Random inspection 1 211
processing wastage
sum rejected quantity mixed to
Rework 2 1 Random inspection 1 211
good qty
Barcode verification Inspect every job
Rejection 2 Barcode readability F Garade 1 2 212
on line printing
Cutting operator wrong size
Rejection 2 1 Random inspection 2 212
selection
CS recheck the all details with PO
Recheck 2 Data entry mistake 1 2 212
details
Goods rust formed 2 wrong quality box selection 1 Random inspection 2 212
Commitment failure 2 Wrong courier mode selection 1 Supervisor take more responsible 1 211
Commitment failure 2 Missed the booking 1 Supervisor Random inspection 2 212
Customer complaints 2 Manual work 1 Supervisor Random inspection 2 212
Process Owner maintain the

Calibration records / QC Team verify
2 Wrong selection 1 2 212
the Calibration values (Least count /
Acceptable criteria/ Error range & etc.)
Customer Product afected Calibration verification periodically
3 Chemical Spill 2 Proper Storage 2 222

Unknown the Hazards level
in Chemical & End user Allocate separate location for
afected Chemicals
Product Quality, Legality & Avoid Snap of blades usage, control

3 1 2 312
Customer Product & End Safety issues the tools & etc
User afected Monitoring the Sharp tools
Product Quality, Legality &

3 1 Proper buiding maintenance 2 312
Customer Product & End Safety issues
User afected Monitoring the Cabin metal pieces
3 1 Proper buiding maintenance 2 312
Customer Product & End Safety issues Monitoring the damages on the
User afected Glass
Use PPE, Avoid the food & drinks items
Drinking Water, Food items are
3 Avoid the Drinking water, Food 1 in machine / working area. Cleanliness 2 312
consumed in Working area
End user afect items in the Shop floor area inToilets
Action Results
Recommended Actions Responsibility Target Date
Actions
R.P.N.
Occ
Det
Sev
Taken
Supplier ensure the good
packing & arrange the good Purchase
control transport in every
supply
Supplier ensure the good Purchase
packing in every supply
Quality
Quality
Quality
Manual verification before Store

issue & receive
Provide training for Store

employee
Using the calibrated Cutting

instruments for measuring
Production and
First pieces approval Quality
Production and
First pieces approval Quality
Adding checklist in coating Supervisor Post
process. press
Adding checklist in coating Supervisor Post
process. press
Periodic checking of cutting Supervisor Post

blade press
Supervisor Post
press
Supervisor Post
press
Supervisor Post
press
Follow Periodical
Calibrations & Maintain QC Team / Process
History cards review. owner
Proper storage / Handling

instructions display/ Process Owner /
Training for handling/ First Compliance
aid Training Manager
Follow up the record

maintenance for blade Process Owner /
usage & Tools control. Maintenance team
Follow up the proper

maintenance & Proper Process Owner /
House keeping Maintenance team 4-Oct-17
Follow up the proper
Maintain the cleanliness in Process Owner /

entire factory. Maintenance team
Part Number
Part Name
Part Rev
PROCESS RISK ASSESSMENT FOR LASER

Requirements
Process Step : Description Function
Product Process
Stores Material receiving Material Inward No Physical damage,
Correct Documentaion, Inspect

No Physical damage, correct quantity
Correct Documentaion
Inspect correct quantity
Inspection Material Quality Inspection Correct Artwork
Correct Size(Board)
Material Issue Issue the material to production Correct quantity
Correct Material
MR Number
Printing pass 1 To printing graphics & data 2 color Colour as per spec
No dust mark
Printing Pass 2 To printing graphics & data 2 color Colour as per spec
No dust mark
Curing To dry the Ink No Set of
Cutting To cut the tag in desire shape Without bur
Even pressure,
Sharp blade
Sorting Sort the product report wise No Mixup
Packing Pack the product as per report No shortage,
Correct Report
Final Inspection Inspect the Quantity and Quality Correct quantity
Correct Quality
Correct Product
Correct report
Dispatch Ship the goods Good cotton box
Corrct courier mode
On time booking
Correct documents
Correct Output
Customer Complaints

Customer Complaints

Customer Complaints
injury
Customer Complaints
Microbiological Afects the Product Health
Contamination
Customer Complaints
Process Failure Modes and Effects Analysis ( PFMEA )
Team Quality Control

Process Responsibility Moorthy.S
Prepared by Senthil Kumar.C
SK ASSESSMENT FOR LASER & THERMAL PRINTSHOP

Potential Cause(s) of
Class
Sev
Potential Failure Mode Potential Efect(s) of Failure Failure, Controls
Occ
Prevention
Cotton box damage Rust form 1 Unsuitable Packaging 1
Roll bend Return to Supplier 2 Unsuitable Packaging 2
Price higher then PO Delay in production 1 Wrong price in invoice Approved Quotation 1
Quantity less then PO GR Delay 1 Rolls shortage in the box 1
Quantity More the PO GR Delay 1 Rolls Excess in the box 1
Artwork Mismatch Rejection 2 Supplier wrongly selection 1
Size less then PO Rejection 2 Supplier wrongly selection 1
stock not available as per job Minimum stock leval not

Delay in production 2 1
requirement maintained
wrong material issued Rejection 2 Un trained Employee Provide training for employee 1
Can not issue the material on Production delay 1 Without Material Request 1
time
Color darker then sample Rejection 3 Toner selection 1
Color lighter then sample Rejection 3 Toner selection 1
White dots found Segrigation 2 Dust mixed 1
Toner not drying on time Rejection 3 Old stock selected 2
Color darker then sample Rejection 3 Toner selection 1
Color lighter then sample Rejection 3 Toner selection 1
White dots found Segrigation 2 Dust mixed 1
Drying delay Set of 3 Drying delay 2
Knife without sharp Rejection 3 Machine setting 1
Cross cutting Rejection 2 Zero setting failure Periadic calibration of zero setting 1
Cross cutting Rejection 3 Zero setting failure Periadic calibration of zero setting 1
Variables mixing Rework 3 Sorting error 1
Short Quantity, Commitment fail 2 counting mistake 2
Wrongly enter the qty from

Wrong packing details enclosed Quantity diferent 2 1
Order entry
Quantity less then packing Rejected sum quantity
Rework 3 Improve the online QC 2
report processing wastage
Barcode readability F
Barcode reading Grade fail Rejection 3 1
Garade
Finishing size less then actuval Rejection 3 1
selection
Quantity not matching customer Recheck 2 Data entry mistake 1
PO
Cotton box easily damage Goods rust formed 2 wrong quality box selection 1
Wrong courier mode

Delay in delivery to customer Cmmitment failure 3 1
selection
Delay in delivery to customer Cmmitment failure 3 Missed the booking 1
Wrong Invoice enclosed Customer complaints 3 Manual work 1
3 Wrong selection 1
values Customer Product afected Calibration verification periodically
3 Chemical Spill 1
in Chemical & End user Allocate separate location for
Unknown the Hazards afected Chemicals

3 1
Product Quality afects User afected Monitoring the Sharp tools

3 1
Product Quality afects User afected Monitoring the Cabin metal pieces

3 1
Customer Product & End Safety issues Monitoring the damages on the
Product Quality afects User afected Glass
Drinking Water, Food items
Product Quality & Productivity 3 are consumed in Working Avoid the Drinking water, Food 2
afects End user afect area items in the Shop floor area
Quality Control FMEA Number
Moorthy.S Date (Orig.)
Senthil Kumar.C Date (Rev.)
urrent Process Controls Action Results
R.P.N.
Det
Controls Actions
R.P.N.
Occ
Det
Sev
Detection Taken

1 111 Purchase
Visual checking
1 221 Purchase
Visual checking
Purchase order Price 1 111
Manual counting 2 112
Manual counting 2 112
GSM Tester 2 212
2 212
Scale
1 211 Store
Manual stock counting every week
Periodic review of efectiveness of Provide training for

1 211 Store
training employee
2 112
Visual checking
Approved sample enclosed with job Production and
2 312 First pieces approval
card for color ref Quality
Approved sample enclosed with job 1 311
card for color ref
Planned Maintanance monthly once 2 212
Randam inspection from supervisor 1 321
Approved sample enclosed with job Production and

2 312 First pieces approval
card for color ref Quality
Approved sample enclosed with job 1 311
card for color ref
Planned Maintanance monthly once 2 212
Control the machine speed 1 321

Periodic checking of cutting Supervisor Post
Randam Indspection 2 312 blade press
Random inspection of cut sheet 2 212
Random inspection of cut sheet 2 312
Supervisor Post
Random inspection of mixup 1 311 press
Supervisor Post
2 222 press
Visual checking with jabcard And spec/ 1 211
sample.
Randam inspection 1 321
Barcode verification Inspect every job

2 312
on line printing
Randam inspection 2 312
CS recheck the all details with PO 2 212

details
Supervisor Post
Randam inspection 1 211 press
Supervisorr take more responsible 2 312
Supervisorr randam inspection 2 312
Supervisorr randam inspection 2 312

Calibration records / QC Team verify 1 311
the Calibration values (Least count / Follow Periodical
Acceptable criteria/ Error range & etc.) Calibrations & Maintain QC Team / Process
Proper Storage 1 311 Proper storage / Handling

Avoid Snap of blades usage, control 2 312 Follow up the record

the tools & etc maintenance for blade Process Owner /
Proper buiding maintenance 2 312 Follow up the proper

Proper buiding maintenance 2 312 Follow up the proper

Use PPE, Avoid the food & drinks items
in machine / working area. Cleanliness 2 322 Maintain the cleanliness in Process Owner /
inToilets entire factory. Maintenance team
Part Number
Part Name
Part Rev
PROC
Requirements
Product
Stores Material Receiving Material Receiving No Physical Damage
No Physical Damage
Incoming Inspection Material Quality Inspection Size Requirements
Color / Shade Requirements
Material Issue Material issue to Production Base Material issue
Printing To print Graphics & Variable data Specification & Artwork
Cutting Cut into individual pieces Specification & Artwork

Packing Order wise & Size wise Packing Job Card Audit Report
Job Card Quantity, Specification &

Final Inspection Random Inspection Artwork
injury
Microbiological Contamination Afects the Product Health

Process Failure Modes and Effects Ana
Team
Process Responsib
Prepared by
PROCESS RISK ASSESSMENT FOR FLEXO & PFL PRINTSHOP

Requirements
Class
Sev
Potential Failure Mode Potential Efect(s) of Failure
Process
Damages - During Transit /

No composition changes in RM Commitment Failure 2
Handling/ Environment
Commitment Failure & it
Ink Lid open condition may cause the product 2
changes
No Size changes in Base Material Size: Less than PO / more than Afect the Product Quality 1
PO
No shade variation in Base No Shade variation Afect the Product Quality 2

Material
Afect the Product Quality &

As per MRN, Material issued Wrong Material 2
Customer commitment
Afect the Customer

Quantity Mismatch 1
commitment
As per Specification & Artwork Wrong Artwork Afect the Customer product 2
Color variation Afect the Customer product 2
Set of Afect the Customer product 1
As per Specification & Artwork Size variation Afect the Customer product 2
Cutting style Afect the Customer product 2
Cutting method Afect the Customer product 2

As per Job Card Audit Report Mix up Afect the Customer product 2
Mismatch Afect the Customer product 2
Excess / Short Qty Afect the Customer product 2
Quantity less then packing Customer commitment

Quality & Quantity Inspection 2
report Failure
Color shade diferent Afect the Customer product 2
Barcode reading Grade fail Afect the Customer product 2
Finishing size less then actual Afect the Customer product 1
Quantity not matching customer Customer commitment 1

PO Failure
2
Correct Output values Customer Product afected
3
in Chemical & End user
Customer Complaints Unknown the Hazards afected
3
Customer Product & End
Customer Complaints Product Quality afects User afected
3
3
Product Quality & Productivity 3

Customer Complaints afects End user afect
ure Modes and Effects Analysis ( PFMEA )

NTSHOP
Failure, Controls Controls
Occ
Packing standard, Approved
Unsuitable Packaging & Logistics facility will be planned 1 Visual checking
Unapproved Logistics properly
Sealed packing with good quality
Unsuitable Packaging containers used for ink and 1 Visual checking
chemical packing
Supplier adhere to follow the P.O
Incoming inspection not GSM Tester & P.O verification during
& incoming inspection against the 1
efective inspection
P.O
Supplier wrongly selection Supplier adhere to follow the 1 Visual checking

same Lot Number delivery
Warehouse person not Before issue, clearly verify After verification put a sign on the Job
verify the material before 1
material against the Job card card
issue
Warehouse person not Before issue, clearly verify After quantity verification put a sign
verify the material Quantity material quantity against the Job 1 on the Job card
before issue card
C.S Person not verify the C.S team, clearly verify the C.S needs to be ensure the correct
Artwork before enclosed to Artwork before to enclosed with 1 artwork enclosure
Job card the Job card
Supervisor need to confirm the
First strike Approval not Operator need to monitor the color
First Strike Approval process for all 2
done properly level during printing randomly.
jobs
Excess ink & improper Ensure the Curing time & 1 Maintain the uniform ink feed level
drying time Temperature
Improper Cutting First Supervisor need to confirm the Operator needs to be verified the
strike Approval not done First Strike Approval process for all 2 Cutting size as per Specification
properly jobs
Job card verification not Operator needs to be verified the
done Cutting style as per Specification
jobs

Job card verification not Operator needs to be verified the
done Cutting method as per Specification
jobs
Packing Team needs to ensure the
Line clearance not efective Line clearance activity on job to 1 Random inspection knife sharp
job
Job card - Order Audit Job card - Order Audit report &
report & Artwork Artwork verification needs to be 1 Random inspection knife sharp
verification not done done before Weighing & Packing.
Job card - Order Audit

report verification & Approved sample enclosed with job
Weighing Instruments 1 card for color ref
Sampling Qty calibration
not done
Rejected sum quantity Improve the online QC 1 Random inspection

processing wastage
sum rejected quantity 2 Random inspection
mixed to good qty
Barcode readability 'F' Barcode verification Inspect every job
1
Garade on line printing
selection 1 Random inspection

Data entry mistake 1 details

Wrong selection 1 the Calibration values (Least count /
Calibration verification periodically
Chemical Spill 2 Proper Storage

Allocate separate location for
Chemicals

1
Safety issues the tools & etc
Monitoring the Sharp tools
Product Quality, Legality & 1 Proper buiding maintenance

Safety issues
Monitoring the Cabin metal pieces

Safety issues Monitoring the damages on the
Glass
Drinking Water, Food items Use PPE, Avoid the food & drinks items
are consumed in Working Avoid the Drinking water, Food 1 in machine / working area. Cleanliness
area items in the Shop floor area inToilets
FMEA Number
Date (Orig.)
Date (Rev.)
Action Results
R.P.N.
Det

Actions
Occ
Det
Sev
Taken
packing & arrange the good Purchase
1 211 control transport in every
supply
211 Supplier ensure the good
1 Purchase
111 Supplier adhere to follow

1 Quality
the P.O
212 Supplier adhere to follow

2 Quality
the P.O
Printshop Supervisor also Production and

1 211 verified befor receiving the Warehouse
goods from warehouse.
Printshop Supervisor also

verified the material before Production and
1 111 receiving the goods from Warehouse
warehouse.
Before issue the Job card,

1 211 Customer Support
C.S Team need to verify
Operator must ensure the

2 222 Color level maintaining Production
during Printing.
Provide training for
1 111 employee regarding color Production
levelling
Supervisor need to confirm
1 221 the First Strike Approval Production
process for all jobs

1 211
2 212
Production and
2 212 First pieces approval Quality
Production and
1 735
2 745
1 745
1 735
2 212
Follow Periodical
2 222 Proper storage / Handling

2 312 Follow up the record

2 312 Follow up the proper


2 312 Maintain the cleanliness in Process Owner /

n Results
R.P.N.
Part Number
Part Name
Part Rev
PR
Requirements
Product
Stores Material receiving Material Inward No Physical damage,

Correct Documentaion, Inspect
No Physical damage, correct quantity
Inspection Material Quality Inspection Correct Base stock
Material Issue Issue the material to production Correct quantity
Correct Material
Printing To printing data As per Artwork / Spec
No dust mark
Sorting Sort the product report wise No Mixup
Packing Pack the product as per report No shortage,
Final Inspection Inspect the Quantity and Quality Correct quantity
Correct Quality
Correct Product
Dispatch Ship the goods Good cotton box

Corrct courier mode
On time booking
injury
Microbiological Afects the Product Health

Contamination
Process Failure Modes and Effects A
Team
Process Responsib
Prepared by
PROCESS RISK ASSESSMENT FOR RFID PRINTSHOP

Requirements
Class
Sev
Potential Failure Mode Potential Efect(s) of Failure
Process
Cotton box damage Rust form 2
Roll bend Return to Supplier 2
Price higher then PO Delay in production 1

Correct Documentation
Quantity less then PO GR Delay 1
Inspect correct quantity
Quantity More the PO GR Delay 1
Mismatch Rejection 1
stock not available as per job Delay in production 2
requirement
wrong material issued Rejection 2
Can not issue the material on Production delay 1
MR Number time
Printability issues Rejection 1
White dots found Segrigation 2
Variables mixing Rework 2
Short Quantity, Commitment fail 2
Wrong packing details enclosed Quantity diferent 2

Correct Report
Quantity less then packing Rework 1
report
Barcode reading Grade fail Rejection 3
Finishing size less then actuval Rejection 2

Quantity not matching customer Recheck 1
Correct report PO
Cotton box easily damage Goods rust formed 2
Delay in delivery to customer Commitment failure 2
Delay in delivery to customer Commitment failure 2

Correct documents Wrong Invoice enclosed Customer complaints 2
2
Correct Output values Customer Product afected
3
in Chemical & End user
Customer Complaints Unknown the Hazards afected
3
3
3
Product Quality & Productivity 3

Customer Complaints afects End user afect
ilure Modes and Effects Analysis ( PFMEA )

SHOP
Failure, Controls Controls
Occ
Unsuitable Packaging 1
Visual checking
Unsuitable Packaging 1
Visual checking
Wrong price in invoice Approved Quotation 1 Purchase order Price
Rolls shortage in the box 1 Manual counting
Rolls Excess in the box 1 Manual counting
Supplier wrongly selection 1 Visual Checking

Minimum stock leval not 1
maintained Manual stock counting every week
Un trained Employee Provide training for employee 1 Periodic review of efectiveness of
training
Without Material Request 1
Visual checking
Machine speed & Ribbon Approved sample enclosed with job
2
Quality card for color ref
Dust mixed 2 Planned Maintanance monthly once
Sorting error 1 Random inspection of mixup
counting mistake 1
Wrongly enter the qty from Visual checking with jabcard And spec/
1
Order entry sample.
Rejected sum quantity Improve the online QC 1 Randam inspection
processing wastage
Barcode readability F Barcode verification Inspect every job
1
Garade on line printing
Cutting operator wrong size 1 Randam inspection
selection
Data entry mistake 1 details
wrong quality box selection 1 Randam inspection
Wrong courier mode 1 Supervisor take more responsible
selection
Missed the booking 1 Supervisor randam inspection
Supervisor randam inspection
Manual work 1

Wrong selection 1 the Calibration values (Least count /
Calibration verification periodically
Chemical Spill 2 Proper Storage

Allocate separate location for
Chemicals

1
Safety issues the tools & etc
Monitoring the Sharp tools

Safety issues
Monitoring the Cabin metal pieces

Safety issues Monitoring the damages on the
Glass
Drinking Water, Food items Use PPE, Avoid the food & drinks items
are consumed in Working Avoid the Drinking water, Food 1 in machine / working area. Cleanliness
area items in the Shop floor area inToilets
FMEA Number
Date (Orig.)
Date (Rev.)
Action Results
R.P.N.
Det

Actions
Occ
Det
Sev
Taken
1 211 Purchase
2 212 Purchase
1 111
1 111
1 111
2 112
2 212 Store
Provide training for
2 212 Store
employee
2 112
Production and
2 222
Supervisor Post
1 211 press
Supervisor Post
2 212 press
2 212
1 111
1 311
1 211
2 112
Supervisor Post
2 212 press
2 212
1 211
1 211
2 212
Follow Periodical
2 222 Proper storage / Handling

2 312 Follow up the record



2 312 Maintain the cleanliness in Process Owner /

n Results
R.P.N.

Process Risk Assessment - Revised

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Process Risk Assessment - Revised

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RISK ASSESSMENT FOR OFFSET

Damages - During Transit /

No Physical Damage Ink Lid open condition

GSM Less than PO / more than

Correct Shade No shade variation in Board

Correct Size(Board) No Size variation in Board Size less then PO

stock not available as per job

No material changes (As per

Without dust Dots found in printing

Sharp Knife Dust found

Color lighter then sample

No dust mark White dots found

No smudging Color variation

Ink not drying on time

Plate with correct color Font missing

Color lighter then sample

No dust mark White dots found

Plate with correct color Font missing

Matte finish done instead of

Viscocity time more

Packing Pack the product as per report No shortage, Short Quantity,

Wrong packing details enclosed

Correct Quality Color shade diferent

Correct Product Finishing size less then actuval

Quantity not matching customer

Correct courier mode Delay in delivery to customer

On time booking Delay in delivery to customer

Correct documents Wrong Invoice enclosed

Instrument Calibration To get the accurate value accuracy

Chemicals Afect the Customer value Hazards

Customer Complaints Unknown the Hazards

Foreign Body Contamination Afect the Customer value injury

Afect the End User & Customer injury

Supplier adhere to follow the

Periodic review of efectiveness of

Add to vaccum or blower in

Add to vaccum or blower in

Segregation 1 Dust mixed to Ink 1 Planned Maintanance monthly once 2 112

Rejection 2 Wrong ink selected 2 Random inspection from supervisor 1 221

Rejection 2 Old stock selected 1 Random inspection from supervisor 2 212

Random inspection from supervisor

Rejection 2 Not available font 1 Manual checking 1 211

Segrigation 1 Dust mixed to Ink 1 Planned Maintanance monthly once 2 112

Random inspection from supervisor

Rejection 2 Not available font 1 Manual checking 1 211

have the instruction check list with job

Rejection 1 Machine setting 1 Random Indspection 2 112

Rework 2 Sorting error 1 Random inspection of mixup 2 212

Commitment fail 2 counting mistake 1 2 212

Commitment failure 2 Missed the booking 1 Supervisor Random inspection 2 212

Customer complaints 2 Manual work 1 Supervisor Random inspection 2 212

Process Owner maintain the

3 Chemical Spill 2 Proper Storage 2 222

Product Quality, Legality & Avoid Snap of blades usage, control

Product Quality, Legality &

Manual verification before Store

Provide training for Store

Using the calibrated Cutting

Periodic checking of cutting Supervisor Post

Proper storage / Handling

Follow up the record

Follow up the proper

Maintain the cleanliness in Process Owner /