AGENDA Day 1

Introductions
Background information - Robert Hoffmann
Objectives
Introduction to Design FMEA
Understand the system - Diagrams
Functions
P – Diagrams
Design FMEA –Functions, Failure Mode, Effects,
Causes, Controls(for failure modes and causes)

THEME
Day 1
Connector  Design
Terminal and Wire assembly  Design
Wire striped ready  Design
Day 2
Prepare wire  Process
Terminal assembly to wire Process
Assemble wires to connector Process

System Name: Wiring Connector

Understand the system

Diagram or drawing of system

Hierarchy Diagram
Boundary Diagram
Functions
Function Tree
Highest Measurable Function
Functional interface diagrams
System Targets

Transfer function
Ideal Output
Error states
'P' Diagram
System Noises
Range of system noises
Effect of system noise on ideal output

Interface Targets
Sub-system Targets
Hierarchy Diagram System Name: Wiring Connector

VEHICLE

ELECTRICS CHASSIS POWERTRAIN BODY

Engine Vehicle Powertrain Engine Exhaust

Wiring Wiring Control Cooling System
Loom Loom Module

Wiring Wiring
Connector Connector
assy assy Female
(Male) (Male)
Block Assy
Block Assy

Wire with Connector Wire with Connector

Terminals Housing Terminals Housing
(Male) (Male) (Female ) (Female)

Wiring
Terminal Wire Wiring
(Male) Assembly Terminal
(Female)

Wire strands Wire Cover

Boundary Diagram System Name: Wiring Connector

Other
Engine Idle speed
Throttle parameter
compartment control
Body condition
body panel Valve
sensors

Wire and Wire and Engine

Throttle Connector Connector
Control
(3 Wires) (3 Wires)
Position Module
Sensor

Engine Under bonnet

Vibration Engine Humidity
Under bonnet
Movement Temperature

System Boundary
Functions System Name: Wiring Connector

What does the 'Wiring Connector' do?

Brainstorm
Conduct Electricity

Connect Wires

Insulate Terminals

Function Tree System Name: Wiring Connector

Function Measure

1. Conduct Electricity How?

 1.1. Connect Wires How?

1.1.1. Restrain Wiring loom Pull off

load

1.1.2. Position Terminals (axially) Spacing

1.1.3. Contact Mating Terminal Surface

area

1.1.4. Retain Mating Connector Pull apart

load

2. Insulate Wires How?

2.1. Insulate Terminals How?

2.1.1. Separate Terminals (with insulating material) Thickness / Area

Resistance
2.1.2. Cover Terminals (with insulating material) Thickness / Area
Resistance

How does the wire with terminal support the

Wiring Connector System Functions?

Function Tree System Name: Wire with Terminal
Function Measure

1. Conduct Electricity How? .

1.1. Connect Wires How? .

1.1.1. Position Terminals (lengthwise) Distance

1.1.2. Crimp Wire (at wire to terminal interface) Profile /

Pull off Force

1.1.3. Squeeze Terminal Interference

(at terminal to terminal interface) / Push in force

2. Insulate Wires How?

2.1.1. Restrain Wire Insulation Sleeve (Crimp Sleeve) Pull

off load

How does the Wire Assembly support the Wiring Connector

System Functions and the wire with terminal Sub-system
Functions?
Function Tree System Name: Wire Assembly
Function Measure

1. Conduct Electrical current How? .

1.1. Allow Wire Crimping How? .

1.1.1. Bare Crimp Surface (ready for crimping) Contact

Area

1.1.2. Position Wire End (ready for crimping) Wire

Length

2. Insulate Wires How? .

2.1. Cover Wires (with insulating material) Thickness /

Resistance

2.2 Minimise Bare Wire (to allow crimping) Length of Bare Wire
When completing a design FMEA the following secondary functions should be
considered.
Has any corporate or regulatory target been set?
Has a program specific target been set?
Has a design feature specifically been created to satisfy the potential secondary
function?
Should there be a design feature to satisfy the requirement?
Do not try to make a feature fit these requirements.

POTENTIAL SECONDARY FUNCTIONS

1. Perform Safely
2. Perform transparently (to occupants)
2.1. Perform without physical discomfort
2.2. Drive acceptably
3. Assemble Easily
4. Ease Service ability
5. Prevent Tampering
6. Prevent Unauthorised Access
7. Feel Secure
8. Satisfy occupant ergonomics
9. Ease Recycleability
10. Ease Traceability
11. Achieve Electro-Magnetic Compatibility (EMC)
12. Achieve acceptable craftsmanship standards
13. Achieve acceptable underhood tidiness standards
14. Achieve acceptable NVH standards
14.1. Be free from ‘Squeak and Rattle’
14.2. Achieve acceptable sound quality
15. Achieve acceptable crashworthiness
16. Minimise environmental impact
17. Avoid System interactions
Functional interface diagrams System Name: Wiring Connector (both Parts)

Connection
Current
Conduct Electricity
Connect Wires
Contact Mating Terminal

Terminal Terminal

Conduct Electricity Conduct Electricity

Connect Wires Connect Wires
Wire Position Terminals Position Terminals Wire
(axially) (axially)

Insulate Wires Insulate Wires

Conduct Electricity Insulate Terminals Insulate Terminals Conduct Electricity
Connect Wires Separate Terminals Separate Terminals Connect Wires
Restrain Wiring loom Restrain Wiring loom

Connector Connector

Insulate Wires Conduct Electricity Insulate Wires

Insulate Terminals Connect Wires Insulate Terminals
Cover Terminals Retain Mating Connector Cover Terminals

EARTHING EARTHING
System Targets
SURFACE System Name: Wiring Connector (both Parts) SURFACE

System Target

Conduct Electricity ------- 0 to 5V at xx Amps

Continuously when requested
Max % voltage error = x %
Underbonnet temperature range –400C to +1600C ?
 System Requirements to meet target
Connect Wires by
Restraining Wiring loom xN Pull off load
Positioning Terminals (axially) x by y mm Spacing
Contacting Mating Terminal x mm2 Surface area
and x mm Interference
Retaining Mating Connector xN Pull-apart load

System Target
Insulate Wires -------- Min xxx resistance
Continuously
Underbonnet temperature range –400C to +1600C
Humidity range ------

System Requirements to meet target

Insulate Terminals by
Separating Terminals
Covering Terminals
x mm Insulation Thickness over entire area
with xx  Resistance
x mm Insulation Thickness over entire area
with xx  Resistance
 Date: Error States
Description
Wiring Connector FMEA Low Voltage
High Voltage
Function: Oscillating Voltage
. Conduct Electricity… Heat

Input Function Ideal Output

Description Units Description: - Description Units
Conduct electricity
Applied Signal V Transfer Function Received Signal V
V V
.

Noise Factors Control Factors

Piece to Piece Variation
Pin to socket interference
Connector pull apart load
Crimping contact area
Wear Out
Pin to socket wear
Corrosion of wire in terminal
Connector retention feature…
wear out
Human influences & Duty cycle
Long journeys heating the…
underhood air
Fiddling with wires
Water and Mud splash routes
External Environment
Humidity of surrounding air
Ambient Air temperature
System Interactions
Engine rock (wire stretch)
Fixing to body (Strain on
terminals)
AGENDA Day 2
Connections with yesterday
Questions
Review Objectives
Introduction to Process FMEA
Understand the Process - Diagrams
Functions: - Process Step, Purpose, Requirements
Design FMEA –Functions, Failure Mode, Effects,
Causes, Controls (for failure mode and causes)
THEME
Day 1
Connector  Design
 Terminal and Wire assembly  Design
Wire stripped ready  Design
Day 2
Prepare wire  Process
Terminal assembly to wire Process
Assemble wires to connector Process
PROCESS FMEA
PROCESS FLOW DIAGRAM

OPERATION: Prepare Wire for Crimping

1. Cut 2. Strip 3. Measure

Wire to Wire & Identify
length Wire

1.1 2.1 Transfer 3.1 Measure

Unreel Wire cut wire to whole length
from drum stripper & strip lengths

1.2 2.2 Locate & 3.2

Place wire in hold wire in Discard rejects
cutting jig stripper jig

1.3 2.3 Strip

Cut wire to Wire bare to 3.3 Place OK
length end of wire parts in
container

1.4 2.4 Rotate to

Unload wire present other 3.3 Check
from tooling end of wire container has
identity marked

2.5 Strip
2.6
Unload
Wire bare
wire
to
fromoftooling
end wire
PROCESS FMEA
PROCESS FLOW DIAGRAM

OPERATION: Crimp Terminals onto wire

1. Load terminals 2. Crimp 3.Measure Crimp

& wire terminals to wire & Identify Wire

1.1 Select 2.1 Hold 3.1 Measure

terminal for wire Steady crimp
crimping integrity

1.2 Place 2.2 Carry out 3.2

terminal crimping op Discard rejects
in Jig

1.3 Unload 2.3 Rotate to 3.3 Place OK

Wire from present other parts in
container end of wire container

1.4 Place 2.4 Carry out 3.3 Check

Wire in crimping op container has
crimping jig identity marked

2.5 Unload
wire from
tooling
PROCESS FMEA
PROCESS FLOW DIAGRAM

OPERATION: Assemble wires to Connector

1. Load
wires to 2. Assemble 3. Fasten Connector
assembly jig Connector parts to wire & terminal

1.1 2.1 3.1

1.2 2.2 3.2

1.3 2.3 3.3

1.4 2.4 3.3

2.5
Functions for Process FMEA

For Process FMEA the Function is to complete the step whilst achieving all the requirements set to
achieve the design target.
Step Number Purpose Requirements
1. Cut Wire to length
1.1. Unreel wire from drum To supply wire for loom Wire aligned with jig
Sufficient wire on roll
Wire can be gripped by tooling.

1.2. Place wire in cutting Jig To be aligned for cut Wire square to cutter
No dirt or grease on surface

1.3. Cut wire to length Have length to suit loom Correct Length within tolerance
Square Cut
No damage to sleeve

1.4. Unload wire from tooling To transfer to next op Wire removed from cutting area
No damage to sleeve
2. Strip Wire
2.1. Transfer cut wire to Be ready for stripping Transfer without damage
stripper or contamination

2.2. Locate & hold Ensure wire in correct Wire end in correct location
wire in stripper jig position Wire does not slip if pulled
No damage to sleeve

2.3. Strip Wire bare To allow electrical Correct Length within tolerance
to end of wire conduction to terminal is stripped
when crimped No insulation remains in stripped area
 Core wire not damaged

2.4. Rotate to present To allow other end Rotate without damage

other end of wire to be stripped or contamination

2.5. as 2.3.
2.6. Unload wire To allow next op No damage to sleeve
from tooling Core wire not damaged