• Arun M.Shinde
• R. K Shrivastava

In a today’s competitive word, many manufacturing industries are trying to decrease costs while maintaining quality value and reliability. In the manufacturing industry, correct processes & the well maintained machineries are necessary because downtime can slowdown and stop production. Present work study explore the causes of production of faulty components in the manufacturing industry for enhanced productivity, reliability, and availability. Present work is focused on identifying potential failures modes, of brake pedal lever component of braking system of automobile light motor vehicle using Failure Mode and Effects Analysis (Process- FMEA), Risk Priority Number (RPN). To analyze and identify critical processes in the manufacturing of brake pedal levers by evaluating failure modes and their causes, assessing their impact on reliability, safety, availability, and maintainability, and implementing strategies for process optimization and risk mitigation. This work contains the Process- FMEA of brake pedal lever of automobile considering the manufacturing aspects. In this work, the manufacturing process of brake pedal lever was assessed critically. Causes of manufacturing defects were identified & corrective actions were taken to prevent these defects. Using FMEA tool the process had been corrected. FMEA is a great tool for failure analysis, as it helps to prevent failures or reduce their impact. FMEA has provided the opportunity for the manufacturing of correct component & it ensures the detection of causes of faulty/rejected component. As a result, the quality, reliability and safety of a system or product are improved. This can result in improved customer satisfaction and loyalty, as well as reduced costs and risks associated with failures. This tool provides an analysis of critical part of braking system. The FMEA analysis of brake pedal lever right from in ward of raw material to final inspection has been done. The Cross Functional Team - CFT (having knowledge and understanding of the product or process, its components, functions, interactions, and potential failure modes and effects) of FMEA make brainstorming on the process. Potential causes/modes, effects & corrective actions are identified. The corrective actions have been implemented. After the proper implementation of corrective actions the Risk Priority Number – RPN is calculated. After making the calculation, it was observed that there is significant reduction in RPN No. From this paper focus on a systematic methodology for applying Failure Mode and Effects Analysis (FMEA) to the manufacturing process of the brake pedal lever in an automobile braking system, focusing exclusively on identifying, analyzing, and mitigating potential failure modes to enhance process reliability and efficiency.

Braking system, brake pedal lever, FMEA, RPN, reliability, safety, potential causes

"Failure Mode Effect Analysis (FMEA) of Brake Pedal Lever of Automobile Light Motor Vehicle", International Journal of Emerging Technologies and Innovative Research (www.jetir.org), ISSN:2349-5162, Vol.12, Issue 2, page no.g422-g433, February-2025, Available :http://www.jetir.org/papers/JETIR2502648.pdf

"Failure Mode Effect Analysis (FMEA) of Brake Pedal Lever of Automobile Light Motor Vehicle", International Journal of Emerging Technologies and Innovative Research (www.jetir.org | UGC and issn Approved), ISSN:2349-5162, Vol.12, Issue 2, page no. ppg422-g433, February-2025, Available at : http://www.jetir.org/papers/JETIR2502648.pdf