FC: ____________

PFMEA: 32129-T0A-ALL
PCP: ____________
Cover Sheet
HONDA HARNESS ASSEMBLY
Family: CR-V

FAS Part Number Customer Part Number Drawing Revision Level Part Name
32129 T0A ZZ22 CORD TAIL GATE

Changes Log
Revision Date Reason ECN / PCN
0 24-Apr-15 Pre launch

FM-270-01-01 REV:01 Fecha efectiva: 05/31/04

 2
POTENTIAL
PROCESS FAILURE MODE AND EFFECTS ANALYSIS
CORE TEAM
Q.A. ENGINEER Margarita Salinas
MFGR. ENGINEER Adrian Lievanos
PART NAME: CORD TAIL GATE MTTO. ENGINEER Fernando Betancout
PART NUMBER : REFERENCE TO COVER SHEET Q.C. ENGINEER Jesus Contreras
REVISION LEVEL : REFERENCE TO COVER SHEET PRODUCTION Gabriel Martinez
PRODUCT (s): HARNESSES FAMILY 32129-T0A
MODEL YEAR(S) / VEHICLE(S): 2015 CR-V
PREPARED BY: Adrian Lievanos REVISION DATE: 24-Apr-15
ELABORATION DATE : 24-Apr-15

ACTIONS RESULTS

Ocurrence

Detection
Severity
CURRENT PROCESS RESPONSIBILTY &

OCURRENCE

DETECTION
Class
POTENTIAL FAILURE

RPN

SEVERITY
PROCESS FUNCTION POTENTIAL EFECTS OF FAILURE POTENTIAL CAUSE OF FAILURE CURRENT PROCESS CONTROLS PREVENTION CONTROLS RECOMENDED ACTION TARGET COMPLETION ACTIONS

RPN
MODE
DETECTION DATE TAKEN

10 Raw Material out Receiving inspection

Assembly problems 9 Problems in supplier process 2 Approbal PPAP 7 126
Receiving Inspection specification procedure

Certified operator
First sample by operator
Wrong set up 7 First sample "OK" QA 6 126
Check list
Short Length Tube Exposed Circuits 3

Releasing for work

Incorrect work instruction 6 Releasing for work insttructions by QA 5 90
insttructions by QA

Certified operator
First sample by operator
Wrong set up 7 First sample "OK" QA 6 126
Check list de inicio
Point Outside dimension

Releasing for work

Incorrect work instruction 6 Releasing for work insttructions by QA 5 90
insttructions by QA
Large Length Tube 3 Certified operator
First sample by operator
Wrong set up 7 First sample "OK" QA 6 126
Check list de inicio
Loops

Releasing for work

Incorrect work instruction 6 Releasing for work insttructions by QA 5 90
insttructions by QA

Mixed Material 7 Kan ban / Kit Supply 1st piece inspection 6 126

Bigger size diameter tube Noise 3

20
Cutting of tubing, PVC and cot Wrong Identification 7 ID for each material in each location . 1st piece inspection 4 84

Mixed Material 7 Kan ban / Kit Supply 1st piece inspection 6 378

Smaller size diameter tube Pinched wires 9

Wrong Identification 7 ID for each material in each location 1st piece inspection 4 252

Managment material 8 Work Instruction 1st piece inspection 2 144

Damaged tubing Piched wires 9

Damaged from supplier 2 Standar pack approved 1st piece inspection 2 36

Certified operator
Bad routing on prefeeder 4 1st piece inspection QA 2 32
Work Instruction
Wrong type tubing Assambly problems 4
Certified auditor
Wrong ID by supplier 1 1st piece inspection 2 8
Visual AID (RECEIVING)

Phisical Visual Aid

Wrong Color Visible Wires 2 Wrong set up 4 Quality Criteria for OK & NG parts 2 16
1st piece by QA

Wrong Kan Ban 5 Validation of Tec Docs vs cutting sheet by QA First piece inspection 2 20
Short Branch

Wrong Set up 3 CCIS II First piece inspection 2 54

Wrong Kan Ban 5 Validation of Tec Docs vs cutting sheet by QA First piece inspection 2 90
Shorth length 9
Disassy circuit
Wrong Set up 3 CCIS II First piece inspection 2 54

Wrong Kan Ban 5 Validation of Tec Docs vs cutting sheet by QA First piece inspection 2 90
Broken Circuit
Wrong Set up 3 CCIS II First piece inspection 2 54

Wrong Kan Ban 5 Validation of Tec Docs vs cutting sheet by QA First piece inspection 2 80
Loops * 8
Wrong Set up 3 CCIS II First piece inspection 2 48
Large Length
Wrong Kan Ban 5 Validation of Tec Docs vs cutting sheet by QA First piece inspection 2 70
Branch outside dimension 7
Wrong Set up 3 CCIS II First piece inspection 2 42

Work Instruction Warehouse CCIS II System

Missing ID 2 2 36
Inspection by QA 1st piece inspection by QC

Work Instruction Warehouse CCIS II System

Wrong wire Continuity problems 9 Wrong ID by supplier 3 2 54
Inspection by QA 1st piece inspection by QC

Not use CCIS II System 4 Training for new operators include map skill Audit by QC 2 72

Work Instruction Warehouse CCIS II System

Continuity problems Missing ID 2 2 36
Inspection by QA 1st piece inspection by QC

Work Instruction Warehouse CCIS II System

Incorrect Terminal Not Assy in the connector 9 Wrong ID by supplier 3 2 54
Inspection by QA 1st piece inspection by QC

Not assy in the contraparte Not use CCIS II System 4 Training for new operators include map skill Audit by QC 2 72

Broken strands Wrong Set up 3 CCIS II First piece inspection 2 54

High insulation 9

Not Assy in the connector Wrong Kan Ban 5 Validation of Tec Docs vs cutting sheet by QA First piece inspection 2 90

CCIS II First piece inspection 2 54

Broken Circuits Wrong Set up 3

Page 2 of 7
Low insulation 9
 3
POTENTIAL
PROCESS FAILURE MODE AND EFFECTS ANALYSIS
CORE TEAM
Q.A. ENGINEER Margarita Salinas
MFGR. ENGINEER Adrian Lievanos
PART NAME: CORD TAIL GATE MTTO. ENGINEER Fernando Betancout
PART NUMBER : REFERENCE TO COVER SHEET Q.C. ENGINEER Jesus Contreras
REVISION LEVEL : REFERENCE TO COVER SHEET PRODUCTION Gabriel Martinez
PRODUCT (s): HARNESSES FAMILY 32129-T0A
MODEL YEAR(S) / VEHICLE(S): 2015 CR-V
PREPARED BY: Adrian Lievanos REVISION DATE: 24-Apr-15
ELABORATION DATE : 24-Apr-15

ACTIONS RESULTS

Ocurrence

Detection
Severity
CURRENT PROCESS RESPONSIBILTY &

OCURRENCE

DETECTION
Class
POTENTIAL FAILURE

RPN

SEVERITY
PROCESS FUNCTION POTENTIAL EFECTS OF FAILURE POTENTIAL CAUSE OF FAILURE CURRENT PROCESS CONTROLS PREVENTION CONTROLS RECOMENDED ACTION TARGET COMPLETION ACTIONS

RPN
MODE
DETECTION DATE TAKEN
Broken Circuits Wrong Set up 3

Chopper Test First piece inspection 2 54

Low insulation 9

Wire outside the terminal Wrong Kan Ban 5 Validation of Tec Docs vs cutting sheet by QA First piece inspection 2 90

CCIS II First piece inspection 2 54

30
Automatic Cutting and crimping Wire outside the terminal Wrong Set up 3

High Crimping 9 Chopper Test First piece inspection 2 54

Not Assy in the connector Wrong Kan Ban 5 Validation of Tec Docs vs cutting sheet by QA First piece inspection 2 90

CCIS II System First piece inspection 2 36

Wrong Set -Up 2

Broken strands Chopper Test First piece inspection 2 36

Low Crimping 9

Wrong Kan Ban 5 Validation of Tec Docs vs cutting sheet by QA First piece inspection 2 90

Change spare parts at 10 000 shots per applicator

Disassy circuit Desgaste* Spare parts 2
Preventive Maintenance
Cross Section Test 2 36

Wrong Set -Up 2 CCIS II First piece inspection 2 16

Terminal bent up & down Assambly problems in the conector 4

Change spare parts at 10 000 shots per applicator 1st piece by QC

Desgaste* Spare parts 2 2 16
Preventive Maintenance Cross Section Test by QA

Check list Auditor by QA

Work Instruction by Warehouse 2 72
Check list auditor by QC
Water leaking Material storage not normal conditions 4

Chopper Test First piece inspection 2 72

Damaged seal 9

Validation of Tec Docs vs cutting sheet by QA First piece inspection 2 36

Seal out of the terminal High Crimping 2

CCIS II System First piece inspection 2 36

CCIS II System First piece inspection 2 126

Wrong Seal Size Water leaking 9 Mixed Material 7

Kan ban / Kit Supply 1st piece inspection 2 126

Assy problems in to the connector

Work instruction, visual aids & certified operator

Backward Seal Wrong Set up seal aplication 2 1st piece inspection 2 36
Chopper Test
9
Water leaking

Work instruction, visual aids & certified operator

Missing Seal Water leaking Wrong Set up seal aplication 2 1st piece inspection by QC 2 36
Chopper Test

Almacenamiento de material en condiciones Check list Auditor by QA

Damaged seal Water leaking
no normales 4 Work Instruction by Warehouse
Check list auditor by QC
2 72

Method not followed properly 2 Work instruction, visual aids & certified operator 1st piece inspection by QC 2 0
55
Missing Seal Water leak 9
Manual Seal Insertion
Method not followed properly 2 Work instruction, visual aids & certified operator 1st piece inspection by QC 2 0

Wrong seal Water leaking Mixed Material 7 Kan ban / Kit Supply 1st piece inspection 2 0

Work Instruction Warehouse

Missing ID 2 1st piece inspection by QC 2 36
Inspection by QA

Work Instruction Warehouse

Wrong ID by supplier 3 2 54
Wrong wire Continuity problems 9 Inspection by QA 1st piece inspection by QC

Not use CCIS II System 4 Training for new operators include map skill Audit by QC 2 72

Work Instruction Warehouse CCIS II System

Continuity problems Missing ID 2 2 36
Inspection by QA 1st piece inspection by QC

Work Instruction Warehouse CCIS II System

Incorrect Terminal Not Assy in the connector 9 Wrong ID by supplier 3 2 54
Inspection by QA 1st piece inspection by QC

Page 3 of 7
 4
POTENTIAL
PROCESS FAILURE MODE AND EFFECTS ANALYSIS
CORE TEAM
Q.A. ENGINEER Margarita Salinas
MFGR. ENGINEER Adrian Lievanos
PART NAME: CORD TAIL GATE MTTO. ENGINEER Fernando Betancout
PART NUMBER : REFERENCE TO COVER SHEET Q.C. ENGINEER Jesus Contreras
REVISION LEVEL : REFERENCE TO COVER SHEET PRODUCTION Gabriel Martinez
PRODUCT (s): HARNESSES FAMILY 32129-T0A
MODEL YEAR(S) / VEHICLE(S): 2015 CR-V
PREPARED BY: Adrian Lievanos REVISION DATE: 24-Apr-15
ELABORATION DATE : 24-Apr-15

ACTIONS RESULTS

Ocurrence

Detection
Severity
CURRENT PROCESS RESPONSIBILTY &

OCURRENCE

DETECTION
Class
POTENTIAL FAILURE

RPN

SEVERITY
PROCESS FUNCTION POTENTIAL EFECTS OF FAILURE POTENTIAL CAUSE OF FAILURE CURRENT PROCESS CONTROLS PREVENTION CONTROLS RECOMENDED ACTION TARGET COMPLETION ACTIONS

RPN
MODE
Incorrect Terminal 9 DETECTION DATE TAKEN

Not assy in the contraparte Not use CCIS II System 4 Training for new operators include map skill Audit by QC 2 72

Broken strands Wrong Set up 3 CCIS II First piece inspection 2 54

High insulation 9

Not Assy in the connector Wrong Kan Ban 5 Validation of Tec Docs vs cutting sheet by QA First piece inspection 2 90

3 CCIS II First piece inspection 2 54

Broken Circuits Wrong Set up

Low insulation 9
3 Chopper Test First piece inspection 2 54

Wire outside the terminal Wrong Kan Ban 5 Validation of Tec Docs vs cutting sheet by QA First piece inspection 2 90

CCIS II First piece inspection 2 54

Wire outside the terminal Wrong Set up 3
High Crimping 9 Chopper Test First piece inspection 2 54
60
Manual Crimping
Not Assy in the connector Wrong Kan Ban 5 Validation of Tec Docs vs cutting sheet by QA First piece inspection 2 90

CCIS II System First piece inspection 2 36

Wrong Set -Up 2

Broken strands Chopper Test First piece inspection 2 36

Low Crimping 9

Wrong Kan Ban 5 Validation of Tec Docs vs cutting sheet by QA First piece inspection 2 90

Change spare parts at 10 000 shots per applicator

Disassy circuit Desgaste* Spare parts 2
Preventive Maintenance
Cross Section Test 2 36

Wrong Set -Up 2 CCIS II First piece inspection 2 16

Terminal bent up & down Assambly problems in the conector 4

Change spare parts at 10 000 shots per applicator
1st piece by QC
Desgaste* Spare parts 2 Cross Section Test by 2 16
Preventive Maintenance
QA
Check list Auditor by QA
Work Instruction by Warehouse 2 17
Check list auditor by QC
Almacenamiento de material en condiciones
Water leaking 4
no normales
Chopper Test First piece inspection 2 72
Damaged seal 9

Validation of Tec Docs vs cutting sheet by QA First piece inspection 2 36

Seal out of the terminal High Crimping 2
CCIS II System First piece inspection 2 36

CCIS II System First piece inspection 2 126

Wrong Seal Size Water leaking 9 Mixed Material 7

Kan ban / Kit Supply 1st piece inspection 2 126

Assy problems in to the connector

Work instruction, visual aids & certified operator
Backward Seal 9 Wrong Set up seal aplication 2 1st piece inspection 2 36
Chopper Test
Water leaking

Work instruction, visual aids & certified operator

Missing Seal Water leaking 9 Wrong Set up seal aplication 2 1st piece inspection by QC 2 36
Chopper Test

Visual inspection 100 %,

2 Work instruction, visual aid, certified operator First & last piece OK, 4 56
Rejections
Bad Crimping Defective part Work instruction not followed properly
Visual inspection 100 %,
2 Work instruction, visual aid, certified operator First & last piece OK, 4 56
80 Rejections
7
Central Stripping
Visual inspection 100 %,
Incorrect Set -Up 2 Work instruction, visual aid, certified operator First & last piece OK, 4 56
Rejections
Incorrect Striping Defective part
Visual inspection 100 %,
Work instruction not followed properly 2 Work instruction, visual aid, certified operator First & last piece OK, 4 56
Rejections

Visual inspection 100 %,

Can't be assembled Incorrect Set -Up 2 Work instruction, visual aid, certified operator First & last piece OK, 4 56
Rejections

Damaged Strands
Crimp force monitor, Visual
Continuity problems Work instruction not followed properly 2 Work instruction & certified operator Inspection 100 % First & last 2 28
piece OK, Rejections

90
7
Splice Crimping

Crimp force monitor, Visual

Wrong Circuit Continuity problems Incorrect Set -Up 2 Work instruction & certified operator Inspection 100 % First & last 2 28
piece OK, Rejections

100 % visual inspection,

High insulation Low performance Incorrect Set -Up 2 Work instruction, visual aids & certified operator. crimp force monitorFirst & 2 28
last piece OK, Rejections
Work instruction, visual aid, certified operator, 100% Visual
100 inspection First & last piece OK,
Missing taping Defective part 4 Method not followed properly 2 5 40
Splice Taping Rejections

Page 4 of 7
 5
POTENTIAL
PROCESS FAILURE MODE AND EFFECTS ANALYSIS
CORE TEAM
Q.A. ENGINEER Margarita Salinas
MFGR. ENGINEER Adrian Lievanos
PART NAME: CORD TAIL GATE MTTO. ENGINEER Fernando Betancout
PART NUMBER : REFERENCE TO COVER SHEET Q.C. ENGINEER Jesus Contreras
REVISION LEVEL : REFERENCE TO COVER SHEET PRODUCTION Gabriel Martinez
PRODUCT (s): HARNESSES FAMILY 32129-T0A
MODEL YEAR(S) / VEHICLE(S): 2015 CR-V
PREPARED BY: Adrian Lievanos REVISION DATE: 24-Apr-15
ELABORATION DATE : 24-Apr-15

ACTIONS RESULTS

Ocurrence

Detection
Severity
CURRENT PROCESS RESPONSIBILTY &

OCURRENCE

DETECTION
Class
POTENTIAL FAILURE

RPN

SEVERITY
PROCESS FUNCTION POTENTIAL EFECTS OF FAILURE POTENTIAL CAUSE OF FAILURE CURRENT PROCESS CONTROLS PREVENTION CONTROLS RECOMENDED ACTION TARGET COMPLETION ACTIONS

RPN
MODE
DETECTION DATE TAKEN

110 First & last piece OK,

Short length Can't be assembled 2 Method not followed properly 2 Work instruction, visual aid, certified operator 2 8
Shield Wire Cutting . Rejections

115 First & last piece OK,

Bad splices taping Burning excess 2 Method not followed properly 2 Work instruction, visual aid, certified operator 2 8
Burnt Tube . Rejections CALI-032

Visual inspection 100 %,

Incorrect Set -Up 2 Work instruction, visual aid, certified operator First & last piece OK, 4 56
120 Rejections CALI-032
Incorrect Striping Low performance 7
Shield Wire Stripping . Visual inspection 100 %,
Work instruction not followed properly 2 Work instruction, visual aid, certified operator First & last piece OK, 4 56
Rejections

130 First & last piece OK,

Missing tape Esthetic problem 2 Work instruction not followed properly 2 Work instruction, visual aid, certified operator 2 8
Shield Wire Taping . Rejections

Electrical test 100 %, visual

Low performance 7 Method not followed properly 3 Work instruction, visual aid, poka yoke fixtures 3 63
aids, Rejections
Inverted Circuits
Electrical test 100 %, visual
Can't be assembled 7 Method not followed properly 2 Fixture of Construction ,work instruction, phisycal visual aid 3 42
140 aids, Rejections
Pre-assembly
Detection alignment fixture in
Can't Be Assembled 7 Method not followed properly 2 Work instruction, visual aid poka yoke fixtures alignment 3 42
electrical board, Rejections
Inverted Circuits
Electrical test 100 %, visual
Low performance 7 Bad handling 3 Work instruction, visual aid and pull method 3 63
aids, Rejections
Dimensional board, visual
Loose Tubing Malfunction 4 Method not followed properly 2 Work instruction, visual aid aid, Rejections CALI-032 & 7 56
033, Visual inspection
160
Taping Station Assembly Fixture and Visual aid & Work instruction & certified 100 % dimensional board,
Short/large Branch Can't Be Assembled 5 Method not followed properly 2 5 50
operator detection fixture,
Assembly Fixture and Visual aid & Work instruction & certified 100 % dimensional board,
Grommet not Taping Out of drawing 2 Method not followed properly 2 8 32
operator detection fixture,
Assembly Fixture and Visual aid & Work instruction & certified 100 % dimensional board,
Clip Bad Placed Can't Be Assembled 5 Mixed parts 7 2 70
operator detection fixture,
Assembly Fixture and Visual aid & Work instruction & certified 100 % dimensional board,
Wrong Color Appearance 2 Method not followed properly 2 2 8
operator Rejections

Assembly Fixture and Visual aid & Work instruction & certified 100 % dimensional board,
Clip Out of Position Can't Be Assembled 6 Method not followed properly 2 2 24
operator detection fixture, Rejections

170 100 % dimensional board,

Damaged plate on clip Damaged Carpet 5 Mixed parts 2 Assembly Fixture and Visual aid & certified operator 2 20
Clips Station Rejections

100 % Electrical Board and

Wrong Clip Pass bad pieces as good 7 Method not followed properly 2 VISUAL INSPECTION
Visual Board.
2 28

Large Tie Pass bad pieces as good 7 Method not followed properly 2 VISUAL INSPECTION 100 % VISUAL BOARD. 2 28

100 % Electrical Board and

Harness Missing test. Pass bad pieces as good 7 Method not followed properly 2 VISUAL INSPECTION 2 28
Visual Board.
180
Dimensional Board
harness missing mark of test. Pass bad pieces as good 7 Method not followed properly 2 VISUAL INSPECTION 100 % VISUAL BOARD. 2 28

Test Failure. Pass bad pieces as good 7 Equipment malfunctioning 2 Quality assurance Electrical Program certification. First quality piece 2 28

Missing Label on switch

Customer Complain. 7 Method not followed properly 2 Visual Inspection. Barcode System. 2 28

190 Pass "OK" electrical test with

Customer Complain. 7 Equipment wrong functioning 2 Q.A. Electrical Program & board certification. First quality piece 2 28
Electrical Test incorrect p/n harness

Wrong Revision on program Barcode System and Visual

Customer Complain. 7 Wrong program loaded 2 Visual inspection 2 28
label. Board.

Harness Missing test in level

Pass bad pieces as good 7 Method not followed properly 2 VISUAL INSPECTION barcode system. Q.A Audit 2 28
change

Tape over the label Barcode System and Visual

Customer Complain. 7 Method not followed properly 2 Visual Inspection. 2 28
identification. Board.

200
Harness Missing test. Not Traceability 7 Method not followed properly 2 Visual Inspection. barcode system. Q.A Audit 2 28
Visual Board & Packing

Incorrect standard pack Customer Complain. 7 Method not followed properly 2 Visual Inspection. barcode system. Q.A Audit 2 28

210
Box Missing parts Customer Complain. 7 Method not followed properly 2 Visual Inspection. Dock Audit work Instruction. 2 28
Dock Audit

Page 5 of 7
 Diagrama de flujo de Proceso
Process Flow Chart
Honda Harness #DFP/PFC PFC-32129-T0A-ALL
Cliente Descripción del Producto (Diag. de Flujo de Proceso)
Customer Product Description. PFC# (Process Flow Chart)

Nivel (Número de Parte) 32129-T0A-ALL Plataforma CR-V '15M Fecha de Revision 9-Apr-15
Level (Part Number) Plataform Revision Date

1
Simbología
Simbology.
Revision
Revision
Caracteristicas Criticas del producto y proceso
Operación Operación Combinada Inspección Prueba Electrica Almacen Transporte Critical Characteristic of the Product and Process
Operation Combine Operation Inspection Electrical Test Warehouse Transport # Ope Descripcion de la operacion Equipo/Maq. requerido/Comentarios
Ope# Operation Description Equipment Required/Comments.

10 Receiving Inspection.

,160 ,150 ,140 ,20,30,110. 15 Stock

,170

20 160
20 Cutting of tubing, PVC and cot

30 ,140 ,90 ,80 ,70 ,60 ,55 ,40

30 Automatic cutting and crimping

55 55 Manual Seal Insertion

60 ,140 60 Manual Crimping

75
80
80 Central Stripping

CALF-101 Hoja 6 de 7 FECHA EFECTIVA:12-13-04

 Diagrama de flujo de Proceso
Process Flow Chart
Honda Harness #DFP/PFC PFC-32129-T0A-ALL
Cliente Descripción del Producto (Diag. de Flujo de Proceso)
Customer Product Description. PFC# (Process Flow Chart)

Nivel (Número de Parte) 32129-T0A-ALL Plataforma CR-V '15M Fecha de Revision 9-Apr-15
Level (Part Number) Plataform Revision Date

1
Simbología
Simbology.
Revision
Revision
Caracteristicas Criticas del producto y proceso
Operación Operación Combinada Inspección Prueba Electrica Almacen Transporte Critical Characteristic of the Product and Process
Operation Combine Operation Inspection Electrical Test Warehouse Transport # Ope Descripcion de la operacion Equipo/Maq. requerido/Comentarios
Ope# Operation Description Equipment Required/Comments.

9 90 Splice Crimping
0

100 140 100 Splice Taping

110 115 110 Shield Wire Cutting

115 Burnt Tube

120 120 Shield Wire Stripping

130 140 130 Shield Wire Taping

140 140 Pre-Assy

90

160 160 Taping station

170 170 Clips station

18 180 Dimensional Inspection

0

19 190 Electrical Testing

0

20 200 Visual board & Packing

0

210 210 Dock Audit

220 220 Stock Finish Good

230 230 Shipping

CALF-101 Hoja 7 de 7 FECHA EFECTIVA:12-13-04