POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS

(PROCESS FMEA) FMEA Number: FMEA -ASSY- 002

Rev./Date : 2/9/2019
Item: CONSOLE ASSY-FLOOR LHD Process ResponsibilitMr.Ganasekar /Babu Prepared by: Siva perumal

Model Year(s)/Vehicle(s) HCI Key Date 9-Feb-19 EO NO : HH6J0143/05/06/2018

Core Team: NM/GS/SS/SP/MSB

Classification

Occurrence

Occurance
Detection

Detection
Severity

Severity
Current Process
Process Step / Potential Potential Cause(s) Current Process Control Responsibility & target

RPN
s.no Requirements Potential Effect(s) of Failure Controls RPN Recommneded actions Actions taken
Function Failure Mode of Failure (Prevention) (Detection) date

Manufacturing
(Next Process):
1.Production Plan will affect (2)

Customer
1.Qty (Assembly Plant): Supplier Improper
Mismatch No Effects - ( 1) 2 Packing std - 2 Incoming Inspection 6 24 - - - 0

End Customer (on Vechile):

No Effects - ( 1 )

Manufacturing
(Next Process):
1.Material Shortage - (3)

Customer
2.Defects Parts (Assembly Plant): 3 Poor Quality - 2 Incoming Inspection 6 36 - - - 0
No Effects - ( 1) Inspection

End Customer (on Vechile):

No Effects - ( 1 )

1 Receiving of As per customer

Child Parts requirements Manufacturing
(Next Process):
1.Production Plan will affect
( Slight Inconvenience to Process ,
Operation & Operator ) - 2
Customer
(Assembly Plant): Supplier Improper
3.Part Mixup No Effects - ( 1) 2 Packing std - 2 Incoming Inspection 6 24 - - - 0

End Customer (on Vechile):

No Effects - ( 1 )

Manufacturing
(Next Process):
1. Production qty variation ( 6)

Customer
4. Improper (Assembly Plant): 6 Supplier Improper - 1 Visual Inspection 6 36 - - - 0
packing No effect Packing std

End Customer (on Vechile):

No effect

1.Inadequate Verification
Manufacturing information in before approval
(Next Process): Material of Material 1 Material testing 6 36 - - - 0
Reject the Product - 100 % ( 8 ) Requisition Form- requisition
MRF/PO Form-MRF & PO
Customer
(Assembly Plant):
1.Wrong Grade Reject the Product ( 8 ) 6
2.Supplier Supplied - 1 Visual Inspection 6 36 - - - 0
End Customer (on Vechile): wrong grade
Poor quality ( 7 )

Manufacturing
(Next Process):
Reject the Product - 100 % ( 8 )
1.Apperance
Material as per Customer Problem
2 RM Incoming Customer 2.Color (Assembly Plant): 7 - 1 Visual Inspection 6 42 - - - 0
Inspection Specification Mismatch Spec error & Part to be rejected(8)
( Inspection Std ) 2.Supplier supplied
wrong grade
 POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS

(PROCESS FMEA) FMEA Number: FMEA -ASSY- 002

Rev./Date : 2/9/2019
Item: CONSOLE ASSY-FLOOR LHD Process ResponsibilitMr.Ganasekar /Babu Prepared by: Siva perumal

Model Year(s)/Vehicle(s) HCI Key Date 9-Feb-19 EO NO : HH6J0143/05/06/2018

Core Team: NM/GS/SS/SP/MSB

Classification

Occurrence

Occurance
Detection

Detection
Severity

Severity
Current Process
Process Step / Potential Potential Cause(s) Current Process Control Responsibility & target

RPN
s.no Requirements Potential Effect(s) of Failure 1.Apperance Controls RPN Recommneded actions Actions taken
Function Material as per Failure Mode of Failure (Prevention) (Detection) date
RM Incoming Customer 2.Color Problem
2 Inspection Specification Mismatch 7 - 1 Visual Inspection 6 42 - - - 0
2.Supplier supplied
( Inspection Std ) wrong grade
End Customer (on Vechile):
Poor Quality - ( 8)

Manufacturing
(Next Process):
1. Production qty variation ( 6)

Customer
3. Improper (Assembly Plant): 6 1. Improper - 1 Visual Inspection 6 36 - - - 0
packing No effect packing std

End Customer (on Vechile):

No effect

Manufacturing
(Next Process):
No effect ( 1 )

Customer
Improper (Assembly Plant): Proper identification of all
Location No effect 2 Fifo not allowed - 1 location 6 12 - - - 0

End Customer (on Vechile):

No effect

Material
3 Storage Proper location
Manufacturing
(Next Process):
Wasting Production time ( 4)

Customer
Wrong (Assembly Plant): 2 Wrong material - 1 Proper identification of all 6 12 - - - 0
Identification No Effects - ( 1) issue to line location

End Customer (on Vechile):

No Effects - ( 1 )

Manufacturing
(Next Process):
No effect ( 1 )

Customer
Improper (Assembly Plant): Proper identification of all
Location 2 Fifo not allowed - 1 location 6 12 - - - 0
No effect

End Customer (on Vechile):

No effect

Child Part
4 storage Proper location
Manufacturing
(Next Process):
Wasting Production time ( 4)

Customer
Wrong (Assembly Plant): 2 Wrong material - 1 Proper identification of all 6 12 - - - 0
Identification No Effects - ( 1) issue to line location

End Customer (on Vechile):

No Effects - ( 1 )

Manufacturing
(Next Process):
No severe effect (1)
 POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS

(PROCESS FMEA) FMEA Number: FMEA -ASSY- 002

Rev./Date : 2/9/2019
Item: CONSOLE ASSY-FLOOR LHD Process ResponsibilitMr.Ganasekar /Babu Prepared by: Siva perumal

Model Year(s)/Vehicle(s) HCI Key Date 9-Feb-19 EO NO : HH6J0143/05/06/2018

Core Team: NM/GS/SS/SP/MSB

Classification

Occurrence

Occurance
Detection

Detection
Severity

Severity
Current Process
Process Step / Potential Potential Cause(s) Current Process Control Responsibility & target

RPN
s.no Requirements Potential Effect(s) of Failure Controls RPN Recommneded actions Actions taken
Function Failure Mode of Failure (Prevention) (Detection) date

Customer
Not Following (Assembly Plant):
FIFO No Effects - ( 1)

End Customer (on Vechile):

No effect (1)
Releasing Raw
5 Materials & FIFO Follow 4 Wrong material - 1 Visual Inspection 6 24 - - - 0
Child parts Manufacturing issue to line
(Next Process):
No severe effect (6)

Customer
Wrong (Assembly Plant):
Material Issue No Effects - ( 1)

End Customer (on Vechile):

No effect (1)

Manufacturing
(Next Process):
Wasting Production time ( 4)

Moving to Customer
Wrong (Assembly Plant): 4 Not following FIFO - 1 Visual Inspection 6 24 - - - 0
No Effects - ( 1)
Location
End Customer (on Vechile):
No Effects - ( 1 )

Manufacturing
(Next Process):
Wasting Production time ( 4)

Customer
Moving Raw Moving (Assembly Plant): Part coming
6 Materials & Follow 3C without Tag No Effects - ( 1) 4 Without tag - 1 Visual Inspection 6 24 - - - 0
Child Parts
End Customer (on Vechile):
No Effects - ( 1 )

Manufacturing
(Next Process):
1.Production Plan will affect (2)

Customer
Quantity (Assembly Plant): 2 Part Issue problem - 1 Visual Inspection 6 12 - - - 0
mismatch No Effects - ( 1)

End Customer (on Vechile):

No Effects - ( 1 )

Manufacturing
(Next Process):
Part Defect (8)

Customer
Improper (Assembly Plant): Not enough Temperature& Timer
8 preheating done - 1 6 48 - - - 0
Preheating No Effects - ( 1) before shots controller

End Customer (on Vechile):

No Effects - ( 1 )

Preheating
7 (console floor) Proper Preheating
 POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS

(PROCESS FMEA) FMEA Number: FMEA -ASSY- 002

Rev./Date : 2/9/2019
Item: CONSOLE ASSY-FLOOR LHD Process ResponsibilitMr.Ganasekar /Babu Prepared by: Siva perumal

Model Year(s)/Vehicle(s) HCI Key Date 9-Feb-19 EO NO : HH6J0143/05/06/2018

Core Team: NM/GS/SS/SP/MSB

Classification

Occurrence

Occurance
Detection

Detection
Severity

Severity
Current Process
Process Step / Potential Potential Cause(s) Current Process Control Responsibility & target

RPN
s.no Requirements Potential Effect(s) of Failure Controls RPN Recommneded actions Actions taken
Function Failure Mode of Failure (Prevention) (Detection) date

7 Preheating Proper Preheating

(console floor) Manufacturing
(Next Process):
Part Defect (8)

Customer
Out of (Assembly Plant): Overheating due to Temperature& Timer
Temperature No Effects - ( 1) 8 lack of awareness - 1 controller 7 56 - - - 0

End Customer (on Vechile):

No Effects - ( 1 )

Manufacturing
(Next Process):
Fitment problem(6 )

Customer
Free from Flash Flash (Assembly Plant): 6 MSP not followed - 1 Visual Inspection 6 36 - - - 0
Flash ( 8 )

End Customer (on Vechile):

Flash ( 8 )

Manufacturing
(Next Process):
Fitment problem(8)

Customer Low pressure &

(Assembly Plant): Low temperature
Free from short fill Short fill Poor appearance & Fitment problem ( 8 ) 8 and Less Injection - 1 Visual Inspection 6 48 - - - 0
time
End Customer (on Vechile):
Poor appearance ( 8 )

Manufacturing
(Next Process):
Appearance problem ( 6)

Customer Low pressure &

Free from Sink Sink mark (Assembly Plant): 8 Low temperature - 1 Visual Inspection 6 48 - - - 0
mark 100 % product to be Rejected ( 8 ) and Less Injection
time
End Customer (on Vechile):
poor apperance( 6 )

Manufacturing
(Next Process):
100 % product to be Rejected & Fitment ( 8
)
Customer
Injection (Assembly Plant): Checker Visual & Checker
8 Moulding Free from Warpage Warpage 100 % product to be Rejected ( 8 ) 8 MSP not followed Inspection 1 Inspection 6 48 - - - 0
(Console Floor)
End Customer (on Vechile):
Slight inconvenience to the operator ( 1 )

Manufacturing
(Next Process):
100 % product to be Rejected ( 8 )

Customer
Free from Undercut Undercut (Assembly Plant): 8 Operator Mistake - 1 Visual Inspection 6 48 - - - 0
100 % product to be Rejected ( 8 )
 POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS

(PROCESS FMEA) FMEA Number: FMEA -ASSY- 002

Rev./Date : 2/9/2019
Item: CONSOLE ASSY-FLOOR LHD Process ResponsibilitMr.Ganasekar /Babu Prepared by: Siva perumal

Injection
8 Moulding
Model Year(s)/Vehicle(s) HCI Key Date 9-Feb-19 EO NO : HH6J0143/05/06/2018
(Console Floor)

Core Team: NM/GS/SS/SP/MSB

Classification

Occurrence

Occurance
Detection

Detection
Severity

Severity
Current Process
Process Step / Potential Potential Cause(s) Current Process Control Responsibility & target

RPN
s.no Requirements Potential Effect(s) of Failure Controls RPN Recommneded actions Actions taken
Function Failure Mode of Failure (Prevention) (Detection) date
Free from Undercut Undercut 8 Operator Mistake - 1 Visual Inspection 6 48 - - - 0

End Customer (on Vechile):

Slight inconvenience to the operator ( 1 )

Manufacturing
(Next Process):
100 % product to be Rejected ( 8 )

Customer
Free from Flow Flow Mark (Assembly Plant): 8 MSP not followed - 1 Visual Inspection 6 48 - - - 0
Mark 100 % product to be Rejected ( 8 )

End Customer (on Vechile):

Slight inconvenience to the operator ( 1 )

Manufacturing
(Next Process):
Fitment problem ( 6)

Customer
Correct Weight as Weight (Assembly Plant):
per spec Low/High Fitment problem (6) 8 MSP not followed SPC 1 Weight Balance 6 48 - - - 0

End Customer (on Vechile):

No effect ( 1 )

Manufacturing
(Next Process):
Part Defect (8)

Customer Not enough

Improper (Assembly Plant): 8 preheating done - 1 Temperature& Timer 6 48 - - - 0
Preheating No Effects - ( 1) before shots controller

End Customer (on Vechile):

No Effects - ( 1 )
Preheating
9 RR CONSOLE Proper Preheating
COVER VENT Manufacturing
(Next Process):
Part Defect (8)

Customer
Out of (Assembly Plant): Overheating due to Temperature& Timer
Temperature No Effects - ( 1) 8 lack of awareness - 1 controller 6 48 - - - 0

End Customer (on Vechile):

No Effects - ( 1 )

Manufacturing
(Next Process):
Fitment problem(6 )

Customer
Free from Flash Flash (Assembly Plant): 8 MSP not followed - 1 Visual Inspection 6 48 - - - 0
Flash ( 8 )

End Customer (on Vechile):

Flash ( 8 )

Manufacturing
(Next Process):
Fitment problem(6 )

Low pressure &

 POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS

(PROCESS FMEA) FMEA Number: FMEA -ASSY- 002

Rev./Date : 2/9/2019
Item: CONSOLE ASSY-FLOOR LHD Process ResponsibilitMr.Ganasekar /Babu Prepared by: Siva perumal

Model Year(s)/Vehicle(s) HCI Key Date 9-Feb-19 EO NO : HH6J0143/05/06/2018

Core Team: NM/GS/SS/SP/MSB

Classification

Occurrence

Occurance
Detection

Detection
Severity

Severity
Current Process
Process Step / Potential Potential Cause(s) Current Process Control Responsibility & target

RPN
s.no Requirements Potential Effect(s) of Failure Controls RPN Recommneded actions Actions taken
Function Failure Mode of Failure (Prevention) (Detection) date

Customer Low pressure &

Free from short fill Short fill (Assembly Plant): 8 Low temperature - 1 Visual Inspection 6 48 - - - 0
Poor appearance & Fitment problem ( 8 ) and Less Injection
time
End Customer (on Vechile):
Poor appearance ( 8 )

Manufacturing
(Next Process):
Appearance problem ( 6)

Customer Low pressure &

Free from Sink (Assembly Plant): Low temperature
mark Sink mark 100 % product to be Rejected ( 8 ) 8 and Less Injection - 1 Visual Inspection 6 48 - - - 0
time
End Customer (on Vechile):
poor apperance( 6 )

Manufacturing
(Next Process):
100 % product to be Rejected & Fitment ( 8
)
Customer
Free from Warpage Warpage (Assembly Plant): 8 MSP not followed Checker 1 Visual & Checker 6 48 - - - 0
100 % product to be Rejected ( 8 ) Inspection Inspection

End Customer (on Vechile):

Slight inconvenience to the operator ( 1 )
Injection
12 Moulding RR
CONSOLE Manufacturing
COVER VENT (Next Process):
100 % product to be Rejected ( 8 )

Customer
(Assembly Plant):
Free from Undercut Undercut 100 % product to be Rejected ( 8 ) 8 Operator Mistake - 1 Visual Inspection 6 48 - - - 0

End Customer (on Vechile):

Slight inconvenience to the operator ( 1 )

Manufacturing
(Next Process):
100 % product to be Rejected ( 8 )

Customer
Free from Flow Flow Mark (Assembly Plant): 8 MSP not followed - 1 Visual Inspection 6 48 - - - 0
Mark 100 % product to be Rejected ( 8 )

End Customer (on Vechile):

Slight inconvenience to the operator ( 1 )

Manufacturing
(Next Process):
Fitment problem ( 6)

Customer
Correct Weight as Weight (Assembly Plant):
per spec Low/High Fitment problem (6) 8 MSP not followed SPC 1 Weight Balance 6 48 - - - 0

End Customer (on Vechile):

No effect ( 1 )
 POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS

(PROCESS FMEA) FMEA Number: FMEA -ASSY- 002

Rev./Date : 2/9/2019
Item: CONSOLE ASSY-FLOOR LHD Process ResponsibilitMr.Ganasekar /Babu Prepared by: Siva perumal

Model Year(s)/Vehicle(s) HCI Key Date 9-Feb-19 EO NO : HH6J0143/05/06/2018

Core Team: NM/GS/SS/SP/MSB

Classification

Occurrence

Occurance
Detection

Detection
Severity

Severity
Current Process
Process Step / Potential Potential Cause(s) Current Process Control Responsibility & target

RPN
s.no Requirements Potential Effect(s) of Failure Controls RPN Recommneded actions Actions taken
Function Failure Mode of Failure (Prevention) (Detection) date

Manufacturing
(Next Process):
Fitment problem ( 6)

Customer
Free from (Assembly Plant): Operator
Apperance defects Fitment problem (6) 8 unawareness - 1 Visual Inspection 6 48 - - - 0

End Customer (on Vechile):

Slight inconvenience to the operator ( 1)

Manufacturing
(Next Process):
Part Defect (8)

Customer Not enough

Improper (Assembly Plant): 8 preheating done - 1 Temperature& Timer 6 48 - - - 0
Preheating No Effects - ( 1) controller
before shots
End Customer (on Vechile):
No Effects - ( 1 )
Preheating
RR CONSOLE
10 COVER Proper Preheating
WITHOUT Manufacturing
VENT (Next Process):
Part Defect (8)

Customer
Out of (Assembly Plant): Overheating due to Temperature& Timer
Temperature No Effects - ( 1) 8 lack of awareness - 1 controller 6 48 - - - 0

End Customer (on Vechile):

No Effects - ( 1 )

Manufacturing
(Next Process):
Fitment problem(6 )

Customer
Free from Flash Flash (Assembly Plant): 8 MSP not followed - 1 Visual Inspection 6 48 - - - 0
Flash ( 8 )

End Customer (on Vechile):

Flash ( 8 )

Manufacturing
(Next Process):
Fitment problem(6 )

Customer Low pressure &

(Assembly Plant): Low temperature
Free from short fill Short fill Poor appearance & Fitment problem ( 8 ) 8 and Less Injection - 1 Visual Inspection 6 48 - - - 0
time
End Customer (on Vechile):
Poor appearance ( 8 )

Manufacturing
(Next Process):
Appearance problem ( 6)

Customer Low pressure &

Free from Sink Sink mark (Assembly Plant): 8 Low temperature - 1 Visual Inspection 6 48 - - - 0
mark 100 % product to be Rejected ( 8 ) and Less Injection
time
 POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS

(PROCESS FMEA) FMEA Number: FMEA -ASSY- 002

Rev./Date : 2/9/2019
Item: CONSOLE ASSY-FLOOR LHD Process ResponsibilitMr.Ganasekar /Babu Prepared by: Siva perumal

Model Year(s)/Vehicle(s) HCI Key Date 9-Feb-19 EO NO : HH6J0143/05/06/2018

Core Team: NM/GS/SS/SP/MSB

Classification

Occurrence

Occurance
Detection

Detection
Severity

Severity
Current Process
Process Step / Potential Potential Cause(s) Current Process Control Responsibility & target

RPN
s.no Requirements Potential Effect(s) of Failure Controls RPN Recommneded actions Actions taken
Function Failure Mode Lowofpressure
Failure & (Prevention) (Detection) date
Free from Sink Low temperature
mark Sink mark 8 and Less Injection - 1 Visual Inspection 6 48 - - - 0
time
End Customer (on Vechile):
poor apperance( 6 )

Manufacturing
(Next Process):
100 % product to be Rejected & Fitment ( 8
)
Customer
Free from Warpage Warpage (Assembly Plant): 8 MSP not followed Checker 1 Visual & Checker 6 48 - - - 0
100 % product to be Rejected ( 8 ) Inspection Inspection

End Customer (on Vechile):

Slight inconvenience to the operator ( 1 )
Injection
Moulding RR
14 CONSOLE
COVER W/O Manufacturing
VENT (Next Process):
100 % product to be Rejected ( 8 )

Customer
(Assembly Plant):
Free from Undercut Undercut 100 % product to be Rejected ( 8 ) 8 Operator Mistake - 1 Visual Inspection 6 48 - - - 0

End Customer (on Vechile):

Slight inconvenience to the operator ( 1 )

Manufacturing
(Next Process):
100 % product to be Rejected ( 8 )

Customer
Free from Flow Flow Mark (Assembly Plant): 8 MSP not followed - 1 Visual Inspection 6 48 - - - 0
Mark 100 % product to be Rejected ( 8 )

End Customer (on Vechile):

Slight inconvenience to the operator ( 1 )

Manufacturing
(Next Process):
Fitment problem ( 6)

Customer
Correct Weight as Weight (Assembly Plant):
per spec Low/High 8 MSP not followed SPC 1 Weight Balance 6 48 - - - 0
Fitment problem (6)

End Customer (on Vechile):

No effect ( 1 )

Manufacturing
(Next Process):
Fitment problem ( 6)

Customer
Free from (Assembly Plant): 8 Operator - 1 Visual Inspection 6 48 - - - 0
Apperance defects Fitment problem (6) unawareness

End Customer (on Vechile):

Slight inconvenience to the operator ( 1)

Manufacturing
(Next Process):
Part Defect (8)

Not enough
 POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS

(PROCESS FMEA) FMEA Number: FMEA -ASSY- 002

Rev./Date : 2/9/2019
Item: CONSOLE ASSY-FLOOR LHD Process ResponsibilitMr.Ganasekar /Babu Prepared by: Siva perumal

Model Year(s)/Vehicle(s) HCI Key Date 9-Feb-19 EO NO : HH6J0143/05/06/2018

Core Team: NM/GS/SS/SP/MSB

Classification

Occurrence

Occurance
Detection

Detection
Severity

Severity
Current Process
Process Step / Potential Potential Cause(s) Current Process Control Responsibility & target

RPN
s.no Requirements Potential Effect(s) of Failure Controls RPN Recommneded actions Actions taken
Function Failure Mode of Failure (Prevention) (Detection) date

Customer Not enough

Improper (Assembly Plant): 8 preheating done - 1 Temperature& Timer 6 48 - - - 0
Preheating No Effects - ( 1) before shots controller

End Customer (on Vechile):

No Effects - ( 1 )
Preheating
COVER
11 CONSOLE Proper Preheating
UPPER AT Manufacturing
MOLDING (Next Process):
Part Defect (8)

Customer
Out of (Assembly Plant): Overheating due to Temperature& Timer
Temperature No Effects - ( 1) 8 lack of awareness - 1 controller 6 48 - - - 0

End Customer (on Vechile):

No Effects - ( 1 )

Manufacturing
(Next Process):
Fitment problem(6 )

Customer
Free from Flash Flash (Assembly Plant): 8 MSP not followed - 1 Visual Inspection 6 48 - - - 0
Flash ( 8 )

End Customer (on Vechile):

Flash ( 8 )

Manufacturing
(Next Process):
Fitment problem(6 )

Customer Low pressure &

(Assembly Plant): Low temperature
Free from short fill Short fill Poor appearance & Fitment problem ( 8 ) 8 and Less Injection - 1 Visual Inspection 6 48 - - - 0
time
End Customer (on Vechile):
Poor appearance ( 8 )

Manufacturing
(Next Process):
Appearance problem ( 6)

Customer Low pressure &

Free from Sink Sink mark (Assembly Plant): 8 Low temperature - 1 Visual Inspection 6 48 - - - 0
mark 100 % product to be Rejected ( 8 ) and Less Injection
time
End Customer (on Vechile):
poor apperance( 6 )

Manufacturing
(Next Process):
100 % product to be Rejected & Fitment ( 8
)
Customer
(Assembly Plant): Checker Visual & Checker
Free from Warpage Warpage 100 % product to be Rejected ( 8 ) 8 MSP not followed Inspection 1 Inspection 6 48 - - - 0

End Customer (on Vechile):

Slight inconvenience to the operator ( 1 )
COVER
CONSOLE
18 UPPER AT
 POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS

(PROCESS FMEA) FMEA Number: FMEA -ASSY- 002

Rev./Date : 2/9/2019
Item: CONSOLE ASSY-FLOOR LHD Process ResponsibilitMr.Ganasekar /Babu Prepared by: Siva perumal

Model Year(s)/Vehicle(s) HCI Key Date 9-Feb-19 EO NO : HH6J0143/05/06/2018

Core Team: NM/GS/SS/SP/MSB

Classification

Occurrence

Occurance
Detection

Detection
Severity

Severity
Current Process
Process Step / Potential Potential Cause(s) Current Process Control Responsibility & target

RPN
s.no Requirements Potential Effect(s) of Failure Controls RPN Recommneded actions Actions taken
Function Failure Mode of Failure (Prevention) (Detection) date

COVER
18 CONSOLE
UPPER AT Manufacturing
MOLDING (Next Process):
100 % product to be Rejected ( 8 )

Customer
Free from Undercut Undercut (Assembly Plant): 8 Operator Mistake - 1 Visual Inspection 6 48 - - - 0
100 % product to be Rejected ( 8 )

End Customer (on Vechile):

Slight inconvenience to the operator ( 1 )

Manufacturing
(Next Process):
100 % product to be Rejected ( 8 )

Customer
Free from Flow Flow Mark (Assembly Plant): 8 MSP not followed - 1 Visual Inspection 6 48 - - - 0
Mark 100 % product to be Rejected ( 8 )

End Customer (on Vechile):

Slight inconvenience to the operator ( 1 )

Manufacturing
(Next Process):
Fitment problem ( 6)

Customer
Correct Weight as Weight (Assembly Plant):
per spec Low/High Fitment problem (6) 8 MSP not followed SPC 1 Weight Balance 6 48 - - - 0

End Customer (on Vechile):

No effect ( 1 )

Manufacturing
(Next Process):
Fitment problem ( 6)

Customer
Free from (Assembly Plant): 8 Operator - 1 Visual Inspection 6 48 - - - 0
Apperance defects Fitment problem (6) unawareness

End Customer (on Vechile):

Slight inconvenience to the operator ( 1)

Manufacturing
(Next Process):
Part Defect (8)

Customer
Improper (Assembly Plant): Not enough Temperature& Timer
Preheating No Effects - ( 1) 8 preheating done - 1 controller 6 48 - - - 0
before shots
End Customer (on Vechile):
No Effects - ( 1 )
Preheating
COVER
12 CONSOLE Proper Preheating
UPPER MT Manufacturing
MOLDING (Next Process):
Part Defect (8)

Customer
Out of (Assembly Plant): 8 Overheating due to - 1 Temperature& Timer 6 48 - - - 0
Temperature No Effects - ( 1) lack of awareness controller
 POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS

(PROCESS FMEA) FMEA Number: FMEA -ASSY- 002

Rev./Date : 2/9/2019
Item: CONSOLE ASSY-FLOOR LHD Process ResponsibilitMr.Ganasekar /Babu Prepared by: Siva perumal

Model Year(s)/Vehicle(s) HCI Key Date 9-Feb-19 EO NO : HH6J0143/05/06/2018

Preheating
CoreCOVER
Team: NM/GS/SS/SP/MSB
12 CONSOLE Proper Preheating
UPPER MT

Classification

Occurrence
MOLDING

Occurance
Detection

Detection
Severity

Severity
Current Process
Process Step / Potential Potential Cause(s) Current Process Control Responsibility & target

RPN
s.no Requirements Potential Effect(s) of Failure Controls RPN Recommneded actions Actions taken
Function Failure Mode of Failure (Prevention) (Detection) date
Out of Overheating due to Temperature& Timer
Temperature 8 lack of awareness - 1 controller 6 48 - - - 0

End Customer (on Vechile):

No Effects - ( 1 )

Manufacturing
(Next Process):
Fitment problem(6 )

Customer
Free from Flash Flash (Assembly Plant): 8 MSP not followed - 1 Visual Inspection 6 48 - - - 0
Flash ( 8 )

End Customer (on Vechile):

Flash ( 8 )

Manufacturing
(Next Process):
Fitment problem(6 )

Customer Low pressure &

(Assembly Plant): Low temperature
Free from short fill Short fill Poor appearance & Fitment problem ( 8 ) 8 and Less Injection - 1 Visual Inspection 6 48 - - - 0
time
End Customer (on Vechile):
Poor appearance ( 8 )

Manufacturing
(Next Process):
Appearance problem ( 6)

Customer Low pressure &

Free from Sink Sink mark (Assembly Plant): 8 Low temperature - 1 Visual Inspection 6 48 - - - 0
mark 100 % product to be Rejected ( 8 ) and Less Injection
time
End Customer (on Vechile):
poor apperance( 6 )

Manufacturing
(Next Process):
100 % product to be Rejected & Fitment ( 8
)
Customer
(Assembly Plant): Checker Visual & Checker
Free from Warpage Warpage 8 MSP not followed Inspection 1 Inspection 6 48 - - - 0
100 % product to be Rejected ( 8 )

End Customer (on Vechile):

Slight inconvenience to the operator ( 1 )
COVER
CONSOLE
20 UPPER MT Manufacturing
MOLDING (Next Process):
100 % product to be Rejected ( 8 )

Customer
Free from Undercut Undercut (Assembly Plant): 8 Operator Mistake - 1 Visual Inspection 6 48 - - - 0
100 % product to be Rejected ( 8 )

End Customer (on Vechile):

Slight inconvenience to the operator ( 1 )

Manufacturing
(Next Process):
100 % product to be Rejected ( 8 )
 POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS

(PROCESS FMEA) FMEA Number: FMEA -ASSY- 002

Rev./Date : 2/9/2019
COVER
Item:
CONSOLE CONSOLE ASSY-FLOOR LHD Process ResponsibilitMr.Ganasekar /Babu Prepared by: Siva perumal
20
UPPER MT
MOLDING
Model Year(s)/Vehicle(s) HCI Key Date 9-Feb-19 EO NO : HH6J0143/05/06/2018

Core Team: NM/GS/SS/SP/MSB

Classification

Occurrence

Occurance
Detection

Detection
Severity

Severity
Current Process
Process Step / Potential Potential Cause(s) Current Process Control Responsibility & target

RPN
s.no Requirements Potential Effect(s) of Failure Controls RPN Recommneded actions Actions taken
Function Failure Mode of Failure (Prevention) (Detection) date

Customer
Free from Flow Flow Mark (Assembly Plant): 8 MSP not followed - 1 Visual Inspection 6 48 - - - 0
Mark 100 % product to be Rejected ( 8 )

End Customer (on Vechile):

Slight inconvenience to the operator ( 1 )

Manufacturing
(Next Process):
Fitment problem ( 6)

Customer
Correct Weight as Weight (Assembly Plant):
per spec Low/High Fitment problem (6) 8 MSP not followed SPC 1 Weight Balance 6 48 - - - 0

End Customer (on Vechile):

No effect ( 1 )

Manufacturing
(Next Process):
Fitment problem ( 6)

Customer
Free from (Assembly Plant): 8 Operator - 1 Visual Inspection 6 48 - - - 0
Apperance defects Fitment problem (6) unawareness

End Customer (on Vechile):

Slight inconvenience to the operator ( 1)

Manufacturing
(Next Process): - 0
Function Problem( 8 )

Customer
Free from Child Child part (Assembly Plant):
part missing Missing Function Problem ( 8 ) 8 Lack of awareness - 1 Visual Inspection 4 32 - - -

End Customer (on Vechile):

Function problem ( 8 )

Manufacturing
(Next Process): Improper training
Lack of Awareness -
Function Problem ( 8 )

Customer
Free from Improper Improper (Assembly Plant): 8 - - 2 Visual Inspection 3 48 - - - 0
asembly Assembly Function & Fitment Problem ( 8 )
Airvent
13 Assembly End Customer (on Vechile):
No severe effect(2 )

Screw not Screw counter, Daily

Free from Screw Screw Missing End Customer (on Vechile): 8 assembled by the Screw counter 2 check sheet/Visual 2 32
missing
operator Inspection marking
Manufacturing
(Next Process):
Waashout ( 6 )

Customer
Free from screw T-Screw Torque (Assembly Plant): 8 High Torque Torque 1 Torque meter 3 24 - - - 0
Washout Out of Spec Function & Fitment problem ( 6 ) Validation
 POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS

(PROCESS FMEA) FMEA Number: FMEA -ASSY- 002

Rev./Date : 2/9/2019
Item:Airvent CONSOLE ASSY-FLOOR LHD Process ResponsibilitMr.Ganasekar /Babu Prepared by: Siva perumal
13
Assembly
Model Year(s)/Vehicle(s) HCI Key Date 9-Feb-19 EO NO : HH6J0143/05/06/2018

Core Team: NM/GS/SS/SP/MSB

Classification

Occurrence

Occurance
Detection

Detection
Severity

Severity
Current Process
Process Step / Potential Potential Cause(s) Current Process Control Responsibility & target

RPN
s.no Requirements Potential Effect(s) of Failure Controls RPN Recommneded actions Actions taken
Function Failure Mode of Failure (Prevention) (Detection) date
Free from screw T-Screw Torque Torque
Washout Out of Spec 8 High Torque Validation 1 Torque meter 3 24 - - - 0

End Customer (on Vechile):

poor apperance( 8 )
 POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS

(PROCESS FMEA) FMEA Number: FMEA -ASSY- 002

Rev./Date : 2/9/2019
Item: CONSOLE ASSY-FLOOR LHD Process ResponsibilitMr.Ganasekar /Babu Prepared by: Siva perumal

Model Year(s)/Vehicle(s) HCI Key Date 9-Feb-19 EO NO : HH6J0143/05/06/2018

Core Team: NM/GS/SS/SP/MSB

Classification

Occurrence

Occurance
Detection

Detection
Severity

Severity
Process Step / Potential Potential Cause(s) Current Process Current Process Control Responsibility & target

RPN
s.no Function Requirements Failure Mode Potential Effect(s) of Failure of Failure Controls (Detection) RPN Recommneded actions date Actions taken
(Prevention)

Manufacturing
(Next Process): - 0
Function Problem( 8 )

Customer
Free from Child Child part (Assembly Plant):
part missing Missing Function Problem ( 8 ) 8 Lack of awareness - 1 Visual Inspection 2 16 - - -

End Customer (on Vechile):

Function problem ( 8 )

Manufacturing
(Next Process):
Function Problem ( 8 )

Customer
Free from Improper Improper (Assembly Plant): 8 Improper training - 1 Visual Inspection 2 16 - - - 0
asembly Assembly Function & Fitment Problem ( 8 ) Lack of Awareness
Arm rest & Brkt End Customer (on Vechile):
14 support No severe effect(2 )
assembly

Free from Screw Screw not Screw Counter,Daily check

missing Screw Missing End Customer (on Vechile): 8 assembled by the Screw counter 3 sheet/Visual Inspection 2 48
operator marking

Manufacturing
(Next Process):
Waashout ( 6 )

Customer
Free from screw T-Screw Torque (Assembly Plant): 8 High Torque Torque 1 Torque meter 3 24 - - - 0
Washout Out of Spec Function & Fitment problem ( 6 ) Validation

End Customer (on Vechile):

poor apperance( 8 )

Manufacturing
(Next Process): - 0
Function Problem( 8 )

Customer
Free from Child Child part (Assembly Plant):
part missing Missing Function Problem ( 8 ) 8 Lack of awareness - 1 Visual Inspection 2 16 - - -

End Customer (on Vechile):

Function problem ( 8 )

Manufacturing
(Next Process):
Function Problem ( 8 )

Customer
Free from Improper Improper (Assembly Plant): 8 Improper training - 1 Visual Inspection 2 16 - - - 0
Upper Console asembly Assembly Function & Fitment Problem ( 8 ) Lack of Awareness
Front View
16 assy, Cap End Customer (on Vechile):
console No severe effect(2 )
assembly
 POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS

(PROCESS FMEA) FMEA Number: FMEA -ASSY- 002

Rev./Date : 2/9/2019
Item: CONSOLE ASSY-FLOOR LHD Process ResponsibilitMr.Ganasekar /Babu Prepared by: Siva perumal

Model Year(s)/Vehicle(s) HCI Key Date 9-Feb-19 EO NO : HH6J0143/05/06/2018

Core Team: NM/GS/SS/SP/MSB

Classification

Occurrence

Occurance
Detection

Detection
Severity

Severity
Upper Current Process
ProcessConsole
Step / Potential Potential Cause(s) Current Process Control Responsibility & target

RPN
s.no Front View Requirements Potential Effect(s) of Failure Controls RPN Recommneded actions Actions taken
Function Failure Mode of Failure (Detection) date
16 assy, Cap (Prevention)
console
assembly

Free from Screw Screw not Screw Counter, Daily

Screw Missing End Customer (on Vechile): 8 assembled by the Screw counter 3 check sheet/Visual 2 48
missing operator Inspection marking

Manufacturing
(Next Process):
Waashout ( 6 )

Customer
Free from screw T-Screw Torque (Assembly Plant): 8 High Torque Torque 1 Torque meter 3 24 - - - 0
Washout Out of Spec Function & Fitment problem ( 6 ) Validation

End Customer (on Vechile):

poor apperance( 8 )

Manufacturing
(Next Process):
Function Problem( 8 )

Customer
Free from Child Child part (Assembly Plant):
part missing Missing Function Problem ( 8 ) 8 Lack of awareness - 1 Visual Inspection 6 48 - - - 0

End Customer (on Vechile):

Function problem ( 8 )

Manufacturing
(Next Process):
Function Problem ( 8 )

Customer
Free from Improper Improper (Assembly Plant): 8 Improper training - 1 Visual Inspection 6 48 - - - 0
asembly Assembly Function & Fitment Problem ( 8 ) Lack of Awareness

End Customer (on Vechile):

No severe effect(2 )

Free from Screw Screw not Screw counter,Daily check

missing Screw Missing End Customer (on Vechile): 8 assembled by the Screw counter 3 sheet/Visual Inspection 2 48
Arm rest, Cup operator marking
Holder, Strip
16 parking, Wire Manufacturing
cable, Upper (Next Process):
console inside Waashout ( 6 )
assembly
Customer
Free from screw T-Screw Torque (Assembly Plant): 8 High Torque Torque 1 Torque meter 4 32 - - - 0
Washout Out of Spec Function & Fitment problem ( 6 ) Validation

End Customer (on Vechile):

poor apperance( 8 )

Free from wrong Wrong arm rest In assembly Assembly fixture profile vs
wire cable wrong Worng assy of End Customer (on Vechile): 8 assembled by the fixture arm rest 3 actual arm rest profile 2 48
assembly wire cable opeartor profile made verified then start the
assembly process
 Holder, Strip POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS
parking, Wire
16 cable, Upper
console inside (PROCESS FMEA) FMEA Number: FMEA -ASSY- 002
Rev./Date :
assembly 2/9/2019
Item: CONSOLE ASSY-FLOOR LHD Process ResponsibilitMr.Ganasekar /Babu Prepared by: Siva perumal

Model Year(s)/Vehicle(s) HCI Key Date 9-Feb-19 EO NO : HH6J0143/05/06/2018

Core Team: NM/GS/SS/SP/MSB

Classification

Occurrence

Occurance
Detection

Detection
Severity

Severity
Process Step / Potential Potential Cause(s) Current Process Current Process Control Responsibility & target

RPN
s.no Function Requirements Failure Mode Potential Effect(s) of Failure of Failure Controls (Detection) RPN Recommneded actions date Actions taken
(Prevention)

Assembly fixture profile vs

Free from wrong Worng Arm Wrong arm rest In assembly actual arm rest profile
End Customer (on Vechile): 8 assembled by the fixture arm rest 3 2 48
arm rest assembly rest Drive assy opeartor profile made verified then start the
assembly process

Manufacturing
(Next Process):
Function Problem( 8 ) -

Customer
Free from Child Child part (Assembly Plant): 8 Lack of awareness - 1 Visual Inspection 6 48
part missing Missing Function Problem ( 8 )

End Customer (on Vechile):

Function problem ( 8 )

Manufacturing
(Next Process):
Function Problem ( 8 )

Customer
Free from Improper Improper (Assembly Plant): Improper training
asembly Assembly, Function & Fitment Problem ( 8 ) 8 Lack of Awareness - 1 Visual Inspection 6 48

17 Rear Console End Customer (on Vechile):

assembly
No severe effect(2 )

Screw not
Free from Screw Screw Missing End Customer (on Vechile): 8 assembled by the Screw counter 3 Daily check sheet/Visual 2 48
missing operator Inspection marking

Manufacturing
(Next Process):
Waashout ( 6 )

Customer
Free from screw T-Screw Torque (Assembly Plant): Torque
Washout Out of Spec Function & Fitment problem ( 6 ) 8 High Torque Validation 1 Torque meter 3 24 - - - 0

End Customer (on Vechile):

poor apperance( 8 )

Manufacturing
(Next Process):
Function Problem ( 8 )

Improper Customer
Free from Improper Fitment of (Assembly Plant): 8 Improper training - 1 Visual Inspection 6 48 - - - 0
Fitment child parts, Function & Fitment Problem ( 8 ) Lack of Awareness
Screw locking
End Customer (on Vechile):
No severe effect(2 )

Manufacturing
(Next Process):
Shortfill, sinkage,screw miss

Shortfill, Customer
Free from visual Sinkage, screw (Assembly Plant): Visual with inspection
18 Final Inspection appearance missing, All sub 100 % product to be rejected ( 9) 8 Lack of awareness - 1 marking 6 48 - - -
parts and spec
 POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS

(PROCESS FMEA) FMEA Number: FMEA -ASSY- 002

Rev./Date : 2/9/2019
Item: CONSOLE ASSY-FLOOR LHD Process ResponsibilitMr.Ganasekar /Babu Prepared by: Siva perumal

Model Year(s)/Vehicle(s) HCI Key Date 9-Feb-19 EO NO : HH6J0143/05/06/2018

Core Team: NM/GS/SS/SP/MSB

Classification

Occurrence

Occurance
Detection

Detection
Severity

Severity
Process Step / Potential Potential Cause(s) Current Process Current Process Control Responsibility & target

RPN
s.no Function Requirements Failure Mode Potential Effect(s) of Failure of Failure Controls (Detection) RPN Recommneded actions date Actions taken
Shortfill, (Prevention)
Free from visual Sinkage, screw Visual with inspection
18 Final Inspection appearance missing, All sub 8 Lack of awareness - 1 marking 6 48 - - -
parts and spec
End Customer (on Vechile):
Customer disstatification( 8 )

Manufacturing
(Next Process):
Shortfill, sinkage,screw miss

Gloss fixed on the

Upper cover Customer Gloss to be fixed on the final
Free from Upper unlocking with (Assembly Plant): 8 Lack of awareness - 1 Visual with inspection 8 64 imspection location to ensure the Siva Assembly and final 8 1 4 32
cover un locking consolr floor 100 % product to be rejected ( 9) marking gap Completed inspection table to
ensure the unlocking
End Customer (on Vechile):
Customer disstatification( 8 )

Manufacturing Vision tester :

(Next Process): 1.Upper/AT Profiile
Function Problem ( 9 ) sensing by top camera in
vison tester
Customer Wrong part 2.Next process will be
Free from Part spec Upper AT/MT (Assembly Plant): assembly, missing stop
error spec error 100 % product to be rejected ( 9) 8 for assembly, Lack - 3 Visual: 2 48 - - - 0
of awareness Verified by Inspector and
End Customer (on Vechile): tock marking provided on
Customer disstatification( 8 ) the upper AT/MT

Manufacturing Vision tester :

(Next Process): 1.Presence of Cup holder
Function Problem ( 9 ) ring sensing by top
camera through cup
Customer holder ring color (White)
(Assembly Plant): in vison tester.
Missing to 2.Next process will be
Free from sub part Presense of Function & Fitment Problem ( 9 ) 8 assembly, Lack of - 3 stop 2 48 - - - 0
availability cup holder ring awareness
End Customer (on Vechile): Visual:
Customer disstatification( 8 ) Visually Verified by the
operator and Inspector

Manufacturing Vision tester :

(Next Process): 1.Armrest color spec
Function Problem ( 9 ) confirmed by top camera
in vison tester
Customer 2.Next process will be
Free from sub part (Assembly Plant): Wrong part stop
color Arm Rest color Function & Fitment Problem ( 9 ) 8 assembly, Lack of - 3 Visual: 2 48 - - - 0
awareness Visually Verified by the
End Customer (on Vechile): operator and Inspector
Customer disstatification( 8 )

Manufacturing Vision tester :

(Next Process): 1.Armrest Drive
Arm rest spec error ( 9 ) (LHD/RHD) spec
confirmed by top camera
Customer through part profile at
Wrong part Righ side of the vison
Arm Rest Spec (Assembly Plant):
error 100 % product to be rejected ( 9) 8 assembly, Lack of - 2 tester 4 64 - - - 0
awareness 2.Next process will be
End Customer (on Vechile): stop
Customer disstatification( 8 ) Visual:
Visually Verified by the
29 Vision test operator and Inspector
Manufacturing Vision tester :
(Next Process): 1.Vent/Non vent spec
Vent / Non vent spec error ( 9 ) confirmed by side camera
in the vison tester
 POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS

(PROCESS FMEA) FMEA Number: FMEA -ASSY- 002

Rev./Date : 2/9/2019
Item: CONSOLE ASSY-FLOOR LHD Process ResponsibilitMr.Ganasekar /Babu Prepared by: Siva perumal

Model Year(s)/Vehicle(s) HCI Key Date 9-Feb-19 EO NO : HH6J0143/05/06/2018

Core Team: NM/GS/SS/SP/MSB

Classification

Occurrence

Occurance
Detection

Detection
Severity

Severity
Current Process
Process
Vision Step
test / Potential Potential Cause(s) Current Process Control Responsibility & target

RPN
29
s.no Requirements Potential Effect(s) of Failure Controls RPN Recommneded actions Actions taken
Function Failure Mode of Failure (Prevention) (Detection)
Vision tester : date
1.Vent/Non vent spec
confirmed by side camera
in the vison tester
Customer 2.Next process will be
Wrong part stop
Vent/Non vent (Assembly Plant): 8 assembly, Lack of - 2 Visual: 2 32 - - - 0
Spec error 100 % product to be rejected ( 9)
awareness Visually Verified by the
End Customer (on Vechile): operator and Inspector
Customer disstatification( 8 )
Free from spec
error Manufacturing Vision tester :
(Next Process): 1.USB / Power outlet spec
USB / Power outlet spec error ( 9 ) confirmed by side camera
in the vison tester
Customer 2.Next process will be
USB / Power (Assembly Plant): Wrong part stop
outlet Spec 8 assembly, Lack of - 2 Visual: 2 32 - - - 0
error 100 % product to be rejected ( 9) awareness Visually Verified by the
End Customer (on Vechile): operator and Inspector
Customer disstatification( 8 )

Manufacturing Vision tester :

(Next Process):
ALC spec error ( 9 )
ALC Spec error Customer
(Wrong ALC (Assembly Plant):
100 % product to be rejected ( 9)
Gendration)
End Customer (on Vechile):
Customer disstatification( 8 )
1.Presence of old ALC
Label detected by centre
of the sensor.
2.Next process will be
Malfucntioning of stop
8 vison tester, Wrong - 2 Visual: 2 32 - - -
inout Visually Verified by the
operator and Inspector

Manufacturing
(Next Process):

Vison tester:
Repeated ALC 1.Same ALC again not 1.Sensor provided to
Customer verify the ALC Code.
Multi ALC (Assembly Plant): Gendration with sensing by the sensor.
Free from Scanning Gendration 8 same part , Work - 2 2.Next process will be 5 80 Sensore to be provide to detect the same Toprun 2.Once verify the ALC 8 2 2 32
ALC Re-scanning Completed again not accepting the
with same part standard not stop same code by the vison
End Customer (on Vechile): followed Visual: tester
Ensured by visually
 POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS

(PROCESS FMEA) FMEA Number: FMEA -ASSY- 002

Rev./Date : 2/9/2019
Item: CONSOLE ASSY-FLOOR LHD Process ResponsibilitMr.Ganasekar /Babu Prepared by: Siva perumal

Model Year(s)/Vehicle(s) HCI Key Date 9-Feb-19 EO NO : HH6J0143/05/06/2018

Core Team: NM/GS/SS/SP/MSB

Classification

Occurrence

Occurance
Detection

Detection
Severity

Severity
Current Process
Process Step / Potential Potential Cause(s) Current Process Control Responsibility & target

RPN
s.no Requirements Potential Effect(s) of Failure Controls RPN Recommneded actions Actions taken
Function Failure Mode of Failure (Detection) date
(Prevention)

Manufacturing
(Next Process):
Function Problem ( 8 )

Improper Customer
Free from Improper Fitment of (Assembly Plant): 8 Improper training - 1 Visual Inspection 6 48 - - - 0
Fitment child parts, Function & Fitment Problem ( 8 ) Lack of Awareness
Screw locking
End Customer (on Vechile):
No severe effect(2 )

19 PDI inpection
Manufacturing
(Next Process):
ALC spec error ( 9 )

Shortfill, Customer
Free from spec Sinkage, screw (Assembly Plant):
error missing, All sub 100 % product to be rejected ( 9) 8 Lack of awareness Vision tester 1 visual in vision tester 6 48 - - -
parts and spec
End Customer (on Vechile):
Customer disstatification( 8 )

Manufacturing
(Next Process):
Wasting Production time ( 4) 0

Moving to Customer
Proper location Wrong (Assembly Plant): 4 Lack of awareness - 1 Visual Inspection 6 24 - - -
Location No effect ( 1 )

End Customer (on Vechile):

No effect ( 1)
Moving of
Console Floor
20 (Pre delivery
Inspection→St Manufacturing
orage) (Next Process):
1.Production Plan will affect (2)

Customer
Quantity (Assembly Plant):
Proper Quantity mismatch No Effects - ( 1) 2 Part Issue problem - 1 Visual Inspection 7 14 - - - 0

End Customer (on Vechile):

No Effects - ( 1 )
 POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS

(PROCESS FMEA) FMEA Number: FMEA -ASSY- 002

Rev./Date : 2/9/2019
Item: CONSOLE ASSY-FLOOR LHD Process ResponsibilitMr.Ganasekar /Babu Prepared by: Siva perumal

Model Year(s)/Vehicle(s) HCI Key Date 9-Feb-19 EO NO : HH6J0143/05/06/2018

Core Team: NM/GS/SS/SP/MSB

Classification

Occurrence

Occurance
Detection

Detection
Severity

Severity
Current Process
Process Step / Potential Potential Cause(s) Current Process Control Responsibility & target

RPN
s.no Requirements Potential Effect(s) of Failure Controls RPN Recommneded actions Actions taken
Function Failure Mode of Failure (Prevention) (Detection) date

Manufacturing
(Next Process):
Nil

Customer
Quantity (Assembly Plant): 1.Not Followed the Packing
2 1 Visual Inspection 6 12 - - - 0
mismatch No Effects - ( 1) packing standard standard Display

End Customer (on Vechile):

No Effects - ( 1 )

Storage & As per WIP Packing

21 Shipping standard Manufacturing
(Next Process):
100 % product to be Reworked off line and
accepted ( 6 )
Customer
Wrong packing (Assembly Plant): 2 1.Not Followed the Packing 1 Visual Inspection 8 16 - - - 0
standard No Effects - ( 1) packing standard standard Display

End Customer (on Vechile):

No Effects - ( 1 )

AMENDMENT DETAILS

REV.NO. REV.DATE REASON FOR REVISON REMARKS

0 26.12.2018 New Release (E.O.: HH6H0614 / 21.12.2017)

1 09.02.2019 Arm rest & Brkt added (Injection molding process)

2 13.06.2019 FMEA updated Vendor added -Shine Plastic, Upper console assy location cahnged, Torque value revised)

Prepared By : Reviewed By : Approved By :