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Revision 6.

0 2/11/98
System Customer Subsystem Chrysler Motors Corporation Component Supplier Any Company, Inc. Part Name Filter Core Team Brad Anderson,Jerry Benware,Lisa Brown,Ken Caracci,Bill Cox,Fred Jordan,Ken Kratz
C l a s s Potential Cause(s) / Mechanisms of Failure

Design FMEA
Customer Part No. DC-77323-XYZ Code ACI-001 Supplier Part No. A-9514 Design Responsibility Brad Anderson Prepared By Brad A. Anderson
O c c u r D e t e c

Org. Date 2/11/98 Dwg. Rev. 8 Key Date 2/11/98

Page 1 of 2 FMEA No. DFMEA-001

Application/Model Year Sedan / 1998 Date 2/11/98


Action Results R. P. N. Recommended Action(s) Responsibility & Target Completion Date Actions Taken S e v O c c D e t R. P. N.

Item / Function

Potential Failure Mode

Potential Effect(s) of Failure

S e v

Current Design Controls

Filter for Insufficient wax assembly with coverage over B44 to firewall specified surface

Deteriorated life of door leading to: Unsatisfactory appearance due to rust through paint over time, Impaired function of interior door hardware

Insufficient wax thickness specified Inappropriate wax specified

4 Supplier certification 5 set up set up Five piece setup, in-process, end of run study

1 4

16 None 80

N/A 2/11/98

40 None

N/A 2/11/98 Based on test reults (Test #9989) spray head modified to ... 6 2 5 60

Corroded interior lower door panels

Improper oxide coating 6

Entrapped air prevents wax from entering corner/edge access

6 Test spray pattern at startup and after idle periods, and ...

5 180 Add team evaluation Engineering and using production Assembly spray equipment Operations and specified wax 2/18/98 2 48

Spray heads 4 Incomming audit per clogged: Viscosity 200-16 certification, too high, SPC Lot/Qtr Temperature too Laboratory test low, Pressure too low using "worst case" wax and application hole size

72 Add laboratory accelerated corrosion testing Conduct DOE on wax thickness

ABC Labs 2/27/98 Engineering Associates 2/18/98

Test results show specified ... DOE shows 25% variation in specified thickness is acceptable

54

24

Feeder not properly or

Approved By Brad A. Anderson

Date 2/11/98

Revision 6.0 2/11/98


System Subsystem Chrysler Motors Component Supplier Any Company, Inc. Part Name Filter Core Team Brad Anderson,Jerry Benware,Lisa Brown,Ken Caracci,Bill Cox,Fred Jordan,Ken Kratz
C l a s s Potential Cause(s) / Mechanisms of Failure

Design FMEA
Customer Part DC-77323-XYZ Code ACI-001 Supplier Part No. A-9514 Design Responsibility Anderson Brad Prepared By Brad A. Anderson
O c c u r D e t e c

Org. 2/11/98 Dwg. Rev. 8 Key Date 2/11/98

2 of 2 FMEA No. DFMEA-001

Application/Model Year Sedan / 1998 Date 2/11/98


Action Results R. P. N. Recommended Action(s) Responsibility & Target Completion Date Actions Taken S e v O c c D e t R. P. N.

Item / Function

Potential Failure Mode

Potential Effect(s) of Failure

S e v

Current Design Controls

Customer complaint, rework

Inappropriate wax specified

aid investigation non-functioning spray Laboratory test "worst case" and application size Laboratory certification per 200-10

4 140

startup procedure

engineering

140

Entrapped air prevents wax from entering corner/edge access

4 Five piece setup, in-process, end of run study

4 112

Approved By Brad A. Anderson

Date 2/11/98

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