Feleffektsanalys/Failure Mode and Effect Analysis Konstruktion/Design

Bilaga/Appendix: 27488001.
xls Sida/Page: 1(12)
FELEFFEKTSANALYS/FAILURE MODE AND EFFECT ANALYSIS KONSTRUKTION/DESIGN

Volvo Personvagnar AB
Huvudsystem/Main system Artikelbenämning/Part name. Ritn nr/Dwg No. Leverantör/Supplier
PSS120 Interior trim Doorpanel, front and rear N/A Lear

Funktion/Function Datum/Date Utförd av/Issued by Status - hårdvara/Status - hardware Projekt/Project Utgåva/Issue
Door upholstery 04-04-07 Anders Eriksson Approved design Y286 and Y285 1
ARTIKEL/PART FELKARAKTÄRISTIK/CHARACTERISTICS OF FAILURE RATING ÅTGÄRD-STATUS/ACTION-STATUS
Nr/ Funktion/ Feltyp/ Felorsak/ Feleffekt på komponent/syst. Provning/ Po S Pd RPN Rekommenderad åtgärd/ Beslutad åtgärd/ Po S Pd RPN Ansvar
No Function Failure mode Causes of failure Effects of failure on part/syst. Testing Recommendations Decisions taken avd/sign
1 Carrier
Keep all the Pins get broken Pins are overwelded Weak joint - parts 2 5 3 30 0
parts together gets loose, rattle
Pins get broken Pins are overwelded Bad appearance - 2 5 3 30 0
parts gets loose
Parts get loose Too few welding Rattle 2 5 3 30 0
points
Speaker grille gets Different materials Rattle 2 5 4 40 0
loose behaviour
Speaker grille gets Different materials Bad appearance Ageing 2 5 4 40 0
loose behaviour
The parts do not fit Tolerances not taken Process problems 2 7 1 14 0
together care of
Parts not connected Wrong design Rattle 2 5 4 40 0
Parts not connected Wrong design Bad appearance 2 5 6 60 0
Parts not connected Wrong design Poor solidity 2 5 6 60 0
Cover sheet Visible sheet metal Tolerances too big Bad appearance 6 5 2 60 0
metal around the edge
Position panel Carrier too close to Reinforcement wrong Bad appearance 2 5 2 20 0
towards drop glass positioned in the
glass carrier
Carrier too far away Reinforcement wrong Too high road noise 2 5 2 20 0
from the glass positioned in the level
carrier
Provide a Rear side of the Not designed Safety risk 6 10 3 180 Balance solidity and 0J
friendly surface carrier too stiff according to prereq crash demands Salomonss
for crash on
Absorbing/isolat Noise leakage around Too big nominal NVH problems 2 5 5 50 0

ing noise the edge distance
Oregistrerad kopia vid utskrift/
Unregistered copy when printed
Bilaga/Appendix: 27488001.xls Sida/Page: 2(12)


Provide a good Damages in the lower Sensitive surface Bad appearance Taxi test 5 5 3 75 0
aesthetic area area material
Damaged surface Sensitive surface Bad appearance 5 5 9 225 Develop a test 0J

material in the rear material method Salomonss
edge from the belt on
tongue
Colour variations Bad UV resistance Bad appearance Sun- 5 5 4 100 0J
simulatio Salomonss
n, Light on
resistanc
e
Dirt on the panel edge Contact with sealing Bad appearance Resistan 7 5 6 210 Change system Tolerances are 0J
ce to solution or make a calculated and the Salomonss
stain deeper ditch, 7 mm result is approved on
remover depression in the
inner door panel
Glossy appearance Wrong grain/surface Bad appearance Wear- 6 5 3 90 0
from wear material combination resistanc
e
Sink marks Wrong dimension of Bad appearance 2 5 2 20 0

structure
Scratch marks To fine grain. Bad appearance Scratch 2 5 2 20 0
resistanc
e
Crack Wrong material Bad appearance Impact 3 5 3 45 0
choice test
Be properly fixed to Retainer house to Bad appearance 2 5 2 20 0
door week
2 Upper insert


Fixate/position Pins get broken Pins are overwelded Weak joint - parts 2 5 3 30 0
IDO gets loose, rattle
Pins get broken Pins are overwelded Bad appearance - 2 5 3 30 0
parts gets loose
Parts get loose Too few welding Rattle 2 5 3 30 0
points
Parts get loose Too few welding Bad appearance 2 5 3 30 0
points
together care of
Comfortable Delamination Bad shape Bad appearance Adhesion 3 5 5 75 0
impression test
Delamination Wrong foam Bad appearance Adhesion 3 5 5 75 0
test
Too hard Lack of foam Bad feeling 3 3 6 54 0
Colour variations Bad UV resistance Bad appearance Sun- 2 5 2 20 0
simulatio
n, Light
resistanc
e
Dirt on insert on light Sensitive material Bad appearance Resistan 8 5 4 160 Change of material 0J
colours ce to from tricotplastic to Salomonss
stain PUR on
remover
Glossy appearance Wrong grain/surface Bad appearance Wear- 3 5 4 60 0

from wear material combination resistanc
e
Provide fixation Parts get loose Too few welding Rattle 2 5 3 30 0

for grabhandle points



points
together care of
Aesthetic Sink marks Wrong dimension of Bad appearance 2 5 2 20 0
impression structure
3 Lower insert
Part of the Damaged surface Sensitive surface Bad appearance Wear- 4 5 8 160 More robust surface 0J
storage (front: material material resistanc material Salomonss
0,5 l bottle and e on
an A4 map)
Bottle and map do not Wrong shape Poor storage function 3 5 2 30 0

fit
Bottles fall when Wrong shape Poor storage function 5 5 2 50 0
closing door or driving
Fixate to upper Parts get loose Too few welding Rattle 2 5 3 30 0

insert points
points
together care of
Provide fixation Parts get loose Too few welding Rattle 2 5 3 30 0
for grabhandle points

points
together care of



Fixate toward Insert gets loose Too small contact Rattle 6 5 6 180 Design bigger contact 0J
module area around the areas Salomonss
screw on
Insert gets loose Too small contact Bad appearance 6 5 6 180 Design bigger contact 0J
area around the areas Salomonss
screw on
Insert gets loose Too small contact Poor solidity 6 5 6 180 Design bigger contact 0J
area around the areas Salomonss
screw on
Insert gets loose Plastic material gets Rattle 6 5 6 180 Use metal bushings 0J
relaxed Salomonss
on
Insert gets loose Plastic material gets Poor solidity 6 5 6 180 Use metal bushings 0J
relaxed Salomonss
on
Insert gets loose Plastic material gets Bad appearance 6 5 6 180 Use metal bushings 0J
relaxed Salomonss
on
Sealing surface Speaker grille not Pins are overwelded Bad audio 2 5 3 30 0
towards sealed off
speaker grille
Speaker grille not Too few welding Bad audio 2 5 3 30 0

sealed off points
Speaker grille not Different materials Bad audio Ageing- 3 5 3 45 0
sealed off behaviour test
Speaker grille not Tolerances not taken Process problems 2 7 1 14 0
sealed off care of
Fixation for Screws come loose Material relaxes Rattle 4 5 6 120 Improve fixation, 0J
midrange implement j-clip Salomonss
speaker, front on
door (3 screws)



Screws come loose Material relaxes Bad audio 4 5 6 120 Improve fixation, 0J
implement j-clip Salomonss
on
Screws come loose Too high torque Rattle 4 5 6 120 Improve fixation, 0J
on
Screws come loose Too high torque Bad audio 4 5 6 120 Improve fixation, 0J
on
Speaker not properly Wrong Rattle 2 5 3 30 0
fixated design/tolerances not
taken care of for
fixation holes
Speaker not properly Wrong Bad audio 2 5 3 30 0
taken care of for
fixation holes
Speaker not properly Wrong Process problems 2 7 1 14 0
taken care of for
fixation holes
Speaker cable and Poor design of Rattle 2 5 3 30 0
terminal rattles in parking place
variants without
speaker
Speaker incorrectly Possible to fit in Process problem 4 7 1 28 0
fitted wrong position
Speaker incorrectly Possible to fit in Rattle - speaker in 4 5 6 120 Design a fool-proof 0J
fitted wrong position wrong position, wrong location Salomonss
clearance on
Fixation for Tweeter comes loose Poor clip function Bad audio 2 5 6 60 0
tweeter, rear
door


Tweeter comes loose Poor clip function Rattle 2 5 6 60 0
Speaker incorrectly Possible to fit in Process problem 4 7 1 28 0

fitted wrong position
Speaker incorrectly Possible to fit in Rattle - speaker in 4 5 6 120 Design a fool-proof 0J
fitted wrong position wrong position, wrong location Salomonss
clearance on
Speaker cable and Poor design of Rattle 2 5 3 30 0
terminal rattles in parking place
variants without
speaker
Speaker not properly Wrong Rattle 2 5 3 30 0
taken care of for clip
fixings
Speaker not properly Wrong Bad audio 2 5 3 30 0
taken care of for clip
fixings
4 Armrest cpl
Closing & Bad solidity Too few fixing points Rattle 6 5 6 180 Optimize fixing points, 0J
opening door number and positions Salomonss
on
Bad solidity Too few fixing points Bad solidity 6 5 6 180 Optimize fixing points, 0J
number and positions Salomonss
on
Bad solidity Incorrect size of Rattle 2 5 6 60 0
welding pin to the
hole



Bad solidity Incorrect size of Bad solidity 2 5 6 60 0
welding pin to the
hole
Bad solidity Too weak structure Rattle 6 5 6 180 Calculate, increase 0J
thickness Salomonss
on
Bad solidity Too weak structure Bad feeling 6 5 6 180 Calculate, increase 0J
thickness Salomonss
on
Comfort area Too hard Bad choice of Bad feeling 2 5 3 30 0
for arm material
Too hard Not enough foam Bad feeling 2 5 3 30 0
Too short Conflict between Bad feeling 6 5 3 90 0
styling, crash and
ergonomics
To narrow Conflict between Bad feeling 6 5 3 90 0
styling, crash and
ergonomics
Snapping noise, Relative movements, Noise 6 5 6 180 Avoid relative 0J
squeaks between vinyl against abs movements in the Salomonss
armrest and joints, rigid fixations, on
grabhandle or bezel grain contact surface
Snapping noise, Relative movements, Noise 6 5 6 180 Avoid relative 0J

squeaks between vinyl against tpo movements in the Salomonss
armrest and carrier joints, rigid fixations, on
grain contact surface
Positioning and Switch bezel gets Too few fixing points Rattle 2 5 3 30 0
fixating loose
switches
Switch bezel gets Too few fixing points Bad appearance 2 5 3 30 0
loose


Switch bezel gets Pins get broken Rattle 2 5 3 30 0
loose
Switch bezel gets Pins get broken Bad appearance 2 5 3 30 0
loose
Uneven gaps around Tolerances not taken Bad appearance 2 5 3 30 0
the switch knobs care of
Too small&big gaps Tolerances not taken Bad appearance 2 5 3 30 0

around the switch care of
knobs
The switch pack gets Wrong design of clip Rattle 2 5 3 30 0
loose from the bezel
The switch pack gets Wrong design of clip Bad appearance 2 5 3 30 0

loose from the bezel
Provide Unsolid feeling Insufficient structure Bad feeling 2 5 3 30 0

stiffness to door
trim cpl
Unsolid feeling Too few fixing points Bad feeling 2 5 3 30 0
Unsolid feeling To weak fixings pins, Bad feeling 3 5 3 45 0

instead of blades and
ultra/sonic welding
Crash friendly Too sharp armrest Not designed Safety risk 4 10 3 120 Crash test 0J
edge according to prereq Salomonss
on
Scratch marks Wrong material Bad appearance Scratch 4 5 3 60 0
and/or grain test



Glossy appearance Wrong material Bad appearance Wear 4 5 3 60 0
from wear and/or grain test
5 Speaker grille
Cover speaker Grille gets loose Too few fixing pins Rattle 2 5 3 30 0
Grille gets loose Too few fixing pins Bad appearance 2 5 3 30 0
Grille gets loose Pins get broken Rattle 2 5 3 30 0
Grille gets loose Pins get broken Bad appearance 2 5 3 30 0
Cracks in the grille Wrong dimensioned Bad appearance Impact 3 5 3 45 0
test
Resistance to Burning to fast Material structure to Not full fill legal Flammab 1 7 2 14 0
flammability weak demands ility test
6 Bushing
Guide lock rod The lock rod gets Wrong dimension Unlocking not 2 8 3 48 0
stuck possible
The lock rod gets Tolerances not taken Unlocking not 2 8 3 48 0
stuck care of possible
The lock rod gets The bushing is not Unlocking not 2 8 3 48 0
stuck parallel to the carrier possible
surface
Lock rod rattle Wrong dimension Noise 6 5 6 180 New design with 0J
spring-loaded finger Salomonss
on
Lock rod rattle Tolerances not taken Noise 6 5 6 180 New design with 0J
care of spring-loaded finger Salomonss
on
Bushing comes loose Cannot take Bad appearance Heat test 3 5 3 45 0
temperature
variations


Bushing comes loose Tolerances not taken Bad appearance 6 5 3 90 Calculate 0J
care of Salomonss
on
7 Crash pad
Rear door, Crash pad comes Broken pins Rattle 2 5 3 30 0
energy loose
absorbing
Crash pad comes Too few fixing points Rattle 2 5 3 30 0
loose
Too low energy Wrong density Safety risk 2 10 2 40 0
absorbing ability
Too low energy Too small crash pad Safety risk 2 10 2 40 0
absorbing ability
8 Decal strip
Scratches, glossiness Sensitive surface Bad appearance Scratch 6 5 3 90 0
& wear
test
Crack Wrong material Bad appearance Impact 3 5 3 45 0
choice test
Surface sticky Wrong paint Bad appearance Moisture 3 5 3 45
test
Wavy appearance Wrong material Bad appearance Heat test 5 5 5 125 Change material for 0J
choice the plastic carrier Salomonss
from abs to pc/abs on
Attach to the Deco trim gets loose Clip function not good Rattle 4 5 3 60 0
carrier enough



Deco trim gets loose Clip function not good Bad appearance 4 5 3 60 0
enough
Deco trim does not fit Pins wrong positioned Process problem 2 7 1 14 0
Noise between the Relative movements, Customer irritation 7 5 3 105 Avoid relative 0J
decal strip and the tpo against decal strip movements in the Salomonss
carrier material joints, rigid fixations, on
grain contact surface
Noise between the Relative movements, Customer irritation 4 5 3 60 0

decal strip and the vinyl against decal
armrest strip material


Feleffektsanalys/Failure Mode and Effect Analysis Konstruktion/Design

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Bilaga/Appendix: 27488001.

xls Sida/Page: 1(12)

FELEFFEKTSANALYS/FAILURE MODE AND EFFECT ANALYSIS KONSTRUKTION/DESIGN

PSS120 Interior trim Doorpanel, front and rear N/A Lear

Parts not connected Wrong design Bad appearance 2 5 6 60 0

Parts not connected Wrong design Poor solidity 2 5 6 60 0

Absorbing/isolat Noise leakage around Too big nominal NVH problems 2 5 5 50 0

FELEFFEKTSANALYS/FAILURE MODE AND EFFECT ANALYSIS KONSTRUKTION/DESIGN

PSS120 Interior trim Doorpanel, front and rear N/A Lear

Damaged surface Sensitive surface Bad appearance 5 5 9 225 Develop a test 0J

Sink marks Wrong dimension of Bad appearance 2 5 2 20 0

FELEFFEKTSANALYS/FAILURE MODE AND EFFECT ANALYSIS KONSTRUKTION/DESIGN

PSS120 Interior trim Doorpanel, front and rear N/A Lear

Glossy appearance Wrong grain/surface Bad appearance Wear- 3 5 4 60 0

Provide fixation Parts get loose Too few welding Rattle 2 5 3 30 0

Oregistrerad kopia vid utskrift/

FELEFFEKTSANALYS/FAILURE MODE AND EFFECT ANALYSIS KONSTRUKTION/DESIGN

PSS120 Interior trim Doorpanel, front and rear N/A Lear

Bottle and map do not Wrong shape Poor storage function 3 5 2 30 0

Fixate to upper Parts get loose Too few welding Rattle 2 5 3 30 0

Parts get loose Too few welding Bad appearance 2 5 3 30 0

Oregistrerad kopia vid utskrift/

FELEFFEKTSANALYS/FAILURE MODE AND EFFECT ANALYSIS KONSTRUKTION/DESIGN

PSS120 Interior trim Doorpanel, front and rear N/A Lear

Speaker grille not Too few welding Bad audio 2 5 3 30 0

Oregistrerad kopia vid utskrift/

FELEFFEKTSANALYS/FAILURE MODE AND EFFECT ANALYSIS KONSTRUKTION/DESIGN

PSS120 Interior trim Doorpanel, front and rear N/A Lear

FELEFFEKTSANALYS/FAILURE MODE AND EFFECT ANALYSIS KONSTRUKTION/DESIGN

PSS120 Interior trim Doorpanel, front and rear N/A Lear

Speaker incorrectly Possible to fit in Process problem 4 7 1 28 0

Oregistrerad kopia vid utskrift/

FELEFFEKTSANALYS/FAILURE MODE AND EFFECT ANALYSIS KONSTRUKTION/DESIGN

PSS120 Interior trim Doorpanel, front and rear N/A Lear

Snapping noise, Relative movements, Noise 6 5 6 180 Avoid relative 0J

FELEFFEKTSANALYS/FAILURE MODE AND EFFECT ANALYSIS KONSTRUKTION/DESIGN

PSS120 Interior trim Doorpanel, front and rear N/A Lear

Too small&big gaps Tolerances not taken Bad appearance 2 5 3 30 0

The switch pack gets Wrong design of clip Bad appearance 2 5 3 30 0

Provide Unsolid feeling Insufficient structure Bad feeling 2 5 3 30 0

Unsolid feeling To weak fixings pins, Bad feeling 3 5 3 45 0

Oregistrerad kopia vid utskrift/

FELEFFEKTSANALYS/FAILURE MODE AND EFFECT ANALYSIS KONSTRUKTION/DESIGN

PSS120 Interior trim Doorpanel, front and rear N/A Lear

FELEFFEKTSANALYS/FAILURE MODE AND EFFECT ANALYSIS KONSTRUKTION/DESIGN

PSS120 Interior trim Doorpanel, front and rear N/A Lear

Oregistrerad kopia vid utskrift/

FELEFFEKTSANALYS/FAILURE MODE AND EFFECT ANALYSIS KONSTRUKTION/DESIGN

PSS120 Interior trim Doorpanel, front and rear N/A Lear

Noise between the Relative movements, Customer irritation 4 5 3 60 0

Oregistrerad kopia vid utskrift/

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