TABLE - 2

S,D TABLE

controls in – station that will detect discrepant part &

automated controls that will detect discrepant part &

Error (Cause) prevention as a result of fixture design,

station by operator through use of attribute gauging

Gauging performed on setup and first – piece check

Failure Mode or Error (Cause) detection in – station

automatically lock part in station to prevent further

processing through use of attribute gauging (go/no
No current process control; Cannot detect or is not

(go/no – go, manual torque check / clicker wrench,

Failure Mode detection in – station by automated

Error (Cause) detection in – station by automated

through visual / tactile / audible means or post –

through use of variable gauging or by automated

operator through visual / tactile / audible means

– go, manual torque check / clicker wrench, etc)

operator through use of variable gauging or in –

Failure Mode and / or Error (Cause) is not easily

machine design or part design. Discrepant parts

Failure Mode detection in – station by operator

cannot be made because item has been error –

Failure Mode detection post – processing by

Failure Mode detection post – processing by

Failure Mode detection post – processing by

controls that will detect discrepant part and

& prevent discrepant part from being made

Zone Actions to be Initiated Per 1000

lock part to prevent further processing

proofed by process/ product design

notify operator (light, buzzer, etc.).
detected (e.g., random audits)

controls that will detect error

(for set – up causes only)

processing
analyzed
DETECTION
Warrants immediate action with specified time targets to switch over to YELLOW / GREEN

etc)
1 in
ZONE

Warrants action at the earliest to switch over to GREEN ZONE %

Not likely to Problem Problem Problem Problem Problem Error Detection Detection not
No detection Problem Detection
PPM detect at any Detection Post Detection at Detection post Detection post Detection at and / or Problem applicable; Error
opportunity at Source
stage Processing Source Processing Processing Source Prevention Prevention

Likelihood
SEVERITY Al Most Moderately
Very Remote Remote Very Low Low Moderate High Very High Almost Certain
of detection Impossible High

Criteria : Severity of Effect on Product Criteria : Severity of Effect on Process

Effect Effect RANK 10 9 8 7 6 5 4 3 2 1
(Customer Effect) (Manufacturing / Assembly Effect)
Potential failure mode affects safe vehicle operation and
/ or involves noncompliance with government regulation May endanger operator (machine or assembly)
10
without warning Faiulre to Meet without warning Faiulre to Meet
Safety and / or Safety and / or
Potential failure mode affects safe Regulatory Regulatory
vehicle operation and / or involves noncompliance with Requirements May endanger operator (machine or assembly) Requirements
9
government regulation with warning with warning

Loss of primary function (vehicle inoperable, does not

affect safe vehicle operation) 100% of product may have to be scrapped. Line
8
shutdown or stop ship
Loss or
Degradation of Major Disruption
Degradation of primary function (vehicle operable, but at A portion of the production run may
Primary Function
reduced level of performance) have to be scrapped. Deviation from primary
7
process including decreased line speed or added
manpower
Loss of secondary function (vehicle operable, but
comfort / convenience functions inoperable) 100% of production run may have to be reworked
6
Loss or off line and accepted
Degradation of Significant
Degradation of secondary function Secondary Disruption
(vehicle operable, but comfort / convenience functions at Function A portion of the production run may have to be
5
reduced level of performance ) reworked off line and accepted

Appearance or Audible Noise, Vehicle operable, item

does not conform and noticed by most customers (>75%) 100% of production run may have to be reworked
4
in satiation before it is processed
Moderate
Appearance or Audible Noise, Vehicle operable, item Disruption
does not conform and noticed by most customers (50%) A portion of the production run may have to be
Annoyance 3
reworked in – station before it is processed

Appearance or Audible Noise, Vehicle operable, item

does not conform and noticed by discriminating Slight inconvenience to process, operation, or
Minot Disruption 2
customers (<25%) operator

No discernible effect
No Effect No discernible effect No Effect 1