Failure Mode and Effects Analysis

No. REVISION DATE PREP APPROVE PART NAME: OCCURRENCE

1 ORIGINAL 100%
PART NUMBER: VERY FREQUENTLY
FREQUENTLY
MODEL: OCCASIONALLY
ALMOST NEVER
PROCESS INFLUENCE RATING

OCCURRENCE

INFLUENCE
PROCESS POTENTIAL CAUSE OF
No. NAME MAN MACHINE FAILURE MODE THE FAILURES PARTS VEHICLE
 INFLUENCE DETECTION CRITICALITY
100% 5 CRITICAL 5 ALMOST NONE 5 OCCURRENCE
VERY FREQUENTLY 4 VERY GREAT 4 SAMPLE SOFT 4 INFLUENCE 70-125 =S
FREQUENTLY 3 GREAT 3 SAMPLE HARD 3 X DETECTION 30-69 =A
OCCASIONALLY 2 LITTLE 2 100%SOFT 2 CRITICALITY 10-29 =B
ALMOST NEVER 1 ALMOST NONE 1 100%HARD 1 1-9 =C
RATING PREVENTATIVE MEASURES PREVENTATIVE MEASURES
CRITICALITY

ADDITIONAL
DETECTION

CONTROLS

CONTROLS
FACILITIES

FACILITIES
PREVENTATIVE
DESIGN

DESIGN
SAME PROCESS DOWNSTREAM PROCESS JUDGE MEASURES WHO WHEN
30
Failure Mode and Effects Analysis

No. REVISION DATE PREP APPROVE PART NAME: OCCURRENCE

1 ORIGINAL 11/6/98 GJ DN ABC STAMPING 100%
PART NUMBER: VERY FREQUENTLY
C123-456-7890 FREQUENTLY
MODEL: OCCASIONALLY
1999 ABC ALMOST NEVER
PROCESS INFLUENCE RATING

OCCURRENCE

INFLUENCE
PROCESS POTENTIAL CAUSE OF
No. NAME MAN MACHINE FAILURE MODE THE FAILURES PARTS VEHICLE
1 Receive Material o Wrong Type of Material Supplier ships wrong type of Out of spec Questionable durability 1 3

material
Wrong Thickness of Material Supplier ships wrong thickness Parts may not May not assemble 2 3
of material form correctly to vehicle

Wrong Width of Material Supplier ships wrong width of Part may not form correctly May not assemble 1 3
material to vehicle

Non-Conforming Material Damaged goods Effect coating Durability 2 3

Effect dimensions May not assemble 2 3

to vehicle
2 OP10 Blank & Fo o o Wrong Die Incorrect Set-Up Amount and time of Parts will not be created 1 5
feed will be incorrect to assemble

Wrong Program Incorrect Set-Up Amount and time of Parts will not be created 1 5
feed will be incorrect to assemble

Slivers or Slugs Incorrect Set-Up Effect dimensions May not assemble 2 3

to vehicle

Dull Tool Effect dimensions May not assemble 2 3

to vehicle
Excessive Burr Dull Tool Effect dimensions May not assemble 2 3

to vehicle
Wrong Thickness of Material Supplier ships wrong thickness Parts may not form May not assemble 2 3
of material correctly to vehicle

Wrong Width of Material Supplier ships wrong width of Part may form incorrectly or Will not create parts 1 3
material at not at all to assemble or may not
assemble

Inside Diameter Incorrect Broken Punch Parts may form with incorrect May not assemble 2 5
hole size or not at all to vehicle

Wrong Punch Parts may form w/ oversized May not assemble 2 5

or undersized holes to vehicle

Forms Incorrect Incorrect Set-Up May not assemble 2 3

to vehicle
3 OP20 Deburr o o Wrong Media Type Incorrect Set-Up Effect dimensions by leaving May not assemble 2 3
burrs or damage parts forms to vehicle

Wrong Media Size Incorrect Set-Up Effect dimensions by leaving May not assemble 2 3
media stuck in holes - to vehicle
undersized media
Effect dimensions by leaving May not assemble 2 3

burrs on part - oversized media to vehicle

 Wrong Adjuncts Incorrect Set-Up Effect dimensions - May not assemble 1 3
contamination to vehicle
Part may rust Questionable durability 1 3

Insufficient Cycle Time Burrs Effect dimensions May not assemble 2 3

to vehicle

Excessive Cycle Time Forms Incorrect Effect dimensions May not assemble 2 3
to vehicle

Worn Media Contamination Effect dimensions- May not assemble 3 4

undersize media stuck in holes to vehicle

4 OP30 Plate o o Wrong Process Supplier did not follow PMC's Out of spec Questionable durability 2 3
P.O.

Improper cleaning Plating adhesion Out of spec Questionable durability 3 3

Spots Out of spec Questionable durability 3 3

Improper Thickness Under plated Out of spec Questionable durability 2 3

Over plated Out of spec Questionable durability 1 3

Damaged Goods Mishandling of parts May effect dimensions May not assemble 3 3
to vehicle
5 OP40 Sort o Wrong Criteria Damaged goods May effect dimensions May not assemble 1 3

Slivers, Burrs to vehicle

Wrong GO Gauges Undersized condition May effect dimensions May not assemble 1 3
to vehicle

Oversized condition May effect dimensions May not assemble 1 3

to vehicle

6 OP50 Final Audit o Wrong Part Incorrect Set-Up Parts will not fit on functional Will not assemble to 1 5
gauge vehicle
Wrong Functional Gauge Incorrect Set-Up Parts will not fit on functional Will not assemble to 1 5

gauge vehicle
Improper Quality Training Unqualified QC Auditor Pass a rejected part May not assemble 1 5
to vehicle

Bad Material Damaged goods May effect dimensions May not assemble 1 3
to vehicle
Bad Plating Supplier did not meet PMC's Out of spec Questionable durability 1 3

P.O.
Incorrect Forms Damaged goods May effect dimensions May not assemble 1 3

to vehicle
7 OP60 Pack & Shi o Improper Packaging Damaged goods May effect dimensions May not assemble 1 3
to vehicle

Mislabeled Parts Wrong parts or quantity of Out of spec Shut down customer 1 5
parts
Wrong Paperwork Wrong parts or quantity of Out of spec Shut down customer 1 5

parts
 INFLUENCE DETECTION CRITICALITY
100% 5 CRITICAL 5 ALMOST NONE 5 OCCURRENCE
VERY FREQUENTLY 4 VERY GREAT 4 SAMPLE SOFT 4 X INFLUENCE 70-125 =S
FREQUENTLY 3 GREAT 3 SAMPLE HARD 3 X DETECTION 30-69 =A
OCCASIONALLY 2 LITTLE 2 100%SOFT 2 CRITICALITY 10-29 =B
ALMOST NEVER 1 ALMOST NONE 1 100%HARD 1 1-9 =C
RATING PREVENTATIVE MEASURES PREVENTATIVE MEASURES
CRITICALITY

ADDITIONAL
DETECTION

CONTROLS

CONTROLS
FACILITIES

FACILITIES
PREVENTATIVE
DESIGN

DESIGN
SAME PROCESS DOWNSTREAM PROCESS JUDGE MEASURES WHO WHEN
5 15 Verify material to P.O. / o

material certification
4 24 Verify material to P.O. / o 100% visual set-up inspection o
material certification In-process inspection at OP10 o

Measure sample o
4 12 Verify material to P.O. / o 100% visual set-up inspection o
material certification In-process inspection at OP10 o
Measure sample

4 24 Visual receiving inspection o 100% visual set-up inspection o

In-process inspection at OP10 o
4 24 Visual receiving inspection o 100% visual set-up inspection o

In-process inspection at OP10 o

1 5 Verify die # on die face plate o Part measurements at OP40 & OP50 o
First Piece 100% Layout o

1 5 Verify program name w/ set-up o Part measurements at Op40 & OP50 o

instructions
First Piece 100% Layout o

4 24 First Piece 100% Layout o o Part measurements at Op40 & OP50 o

4 24 First Piece 100% Layout o Part measurements at Op40 & OP50 o

Part measurement 1 / hour
4 24 First Piece 100% Layout o o Part measurements at Op40 & OP50 o

Part measurement 1 / hour

4 24 First Piece 100% Layout o o Part measurements at Op40 & OP50 o
Part measurement 1 / hour

4 12 First Piece 100% Layout o Part measurements at Op40 & OP50 o

Part measurement 1 / hour o

4 40 First Piece 100% Layout o Part measurements at Op40 & OP50 o Perform 100% gaging at M/P
Part measurement 1 / hour X OP40 GJ Start

4 40 First Piece 100% Layout o Part measurements at Op40 & OP50 o Perform 100% gaging at M/P

Part measurement 1 / hour X OP40 GJ Start

4 24 First Piece 100% Layout o Part measurements at Op40 & OP50 o

Part measurement 1 / hour

4 24 100% visual set-up inspection o In-process inspection at OP40
Complete Checklist #123

4 24 100% visual set-up inspection o o In-process inspection at OP40

Complete Checklist #123

4 24 100% visual set-up inspection o o In-process inspection at OP40

Complete Checklist #123

4 12 100% visual set-up inspection o In-process inspection at OP40
Complete Checklist #123
4 12 100% visual set-up inspection o In-process inspection at OP40

Complete Checklist #123

4 24 100% visual o In-process inspection at OP40 o
Complete Checklist #123

29
4 24 100% visual o In-process inspection at OP40 o
Complete Checklist #123

4 48 100% visual o In-process inspection at OP40 o Institute Screen Testing Every

Complete Checklist #123 X of Media GJ Month

4 24 Visual inspection and plating o Part measurements at Op40 & OP50 o
measurements by supplier

2 18 Visual inspection and plating o Part measurements at Op40 & OP50 o

measurements by supplier
2 18 Visual inspection and plating o Part measurements at Op40 & OP50 o

measurements by supplier

5 30 Visual inspection and plating o Part measurements at Op40 & OP50 o Measure Sample M/P

measurements by supplier X Each Plating Lot GJ Start

5 15 Visual inspection and plating o Part measurements at Op40 & OP50 o

measurements by supplier

2 18 Visual inspection and plating o Part measurements at Op40 & OP50 o

measurements by supplier
2 6 Complete Checklist Form o Final Audit inspection at OP50

F0000-02
2 6 Complete Checklist Form o Final Audit inspection at OP50
F0000-02

2 6 Complete Checklist Form o Final Audit inspection at OP50

F0000-02

1 5 Complete Checklist Form o

F0000-02
1 5 Complete Checklist Form o

F0000-02
1 5 Complete Checklist Form o
F0000-02

4 12 Complete Checklist Form o

F0000-02
4 12 Complete Checklist Form o

F0000-02
4 12 Complete Checklist Form o

F0000-02
4 12 100% visual sort o
Complete Shipping Checklist
#123
4 20 100% visual sort o
Complete Shipping Checklist
#123
4 20 100% visual sort o

Complete Shipping Checklist

#123

30