Failure Modes and Effects Analysis (Design FMEA)

SCOPE DEFINTION (STEP 1)

Company Name: Subject:

Borgwarner Power tranmission system(Chain)

Engineering Location: DFMEA Start Date: DFMEA ID Number:

Chennai 21-02-2020 FMEA/NPD021D

Customer Name: DFMEA Revision / Date: Design Responsibility:

M&M 24-07-2020 Karthik(dwsign lead)

Model of Year / Platform: Cross-Functional Team Confidential Level:

2023 D22 Bala(Quality); Ramanan(NPD); Manikandan(Design); Sudhakar(Manufacturing); Jaishankar (Program ma Business level/ Confidential

STRUCTURE ANALYSIS (STEP 2) FUNCTION ANALYSIS (STEP 3) FAILURE ANALYSIS (STEP 4) RISK ANALYSIS (STEP 5) OPTIMIZATION (STEP 6)

Detection (D) of FC/FM

Occurance (O) of FC
Severity (S) of FE
Status:
serial number #

Occurance (O)

Detection (D)
3. Next Lower level or (Untouched,

Severity (s)
DFMEA AP
3. Next Lower Level 1. Failure Effects (FE)
Characteristic Type 1. Next Higher Level 2. Focus Element 3. FAILURE CAUSE (FC) Target under Action Taken
Function and to Next Higher Level 2. FAILURE MODE (FM) of Current Prevention Current Detection Responsibile Completion

AP
1. Next Higher Level 2. Focus Element (Geometry, Material, Function and Function and of the Next Lower Prevention Action Detection Action Completion consideration, with Pointer to Remarks
Requirement or Element and/or the Focus Element Controls Controls Person Date
Surface Finish, Requirement Requirement Element or Characteristic Date in progress, Evidence
Characteristic Vechile End User
Coating, etc.) completed,
discarded)

Power Chain Bush(Size) To transmit To transmit Bush, Which 1.Frequent noise Chain may worn out. Improper seating of Bush OD is Chain wear
transmission power From power from makes the chain and vibration bush in the teeth designed to test, and
system engine to wheels. engine cranshaft to seat on the from the chain. radius(Due to high design (NVH), Noise
to cam shaft(4W) Sprocket 2. Degradation of OD size) requirements as vibration test
completely to primary function per tolerance procedure
1
promote smooth 7 sheet specifed 2 with 2 L NA NA NA NA NA NA NA NA NA NA NA NA
transmission of by Customer. equipment
power. (FRM/NPD/T09 available for
available. testing.

634981402.xlsx: Blank Template - DFMEAForm: AIAG-SAE-VDA 1 of 2 Organization's distribution policy statement.

 Failure Modes and Effects Analysis (PROCESS FMEA)
SCOPE DEFINTION (STEP 1)

Borgwarner Assembly of chain

Company Name: Subject:

Chennai 17-01-2020 FRM/12/NPD/FMEA

Engineering Location: PFMEA Start Date: PFMEA ID Number:

M&M 22-05-2020 S.Sudhakar(Manufacturing Lead)

Customer Name: PFMEA Revision Date: Process Responsibility:

2022D15 Ramanan(NPD); Sudhakar(Manufacturing); Ravi (Quality) Business use/ Confidential

Co Model of Year / Platform: Cross-Functional Team Confidential Level:
nti
nu
ou
s
im
STRUCTURE ANALYSIS FUNCTION ANALYSIS FAILURE ANALYSIS RISK ANALYSIS OPTIMIZATION
pro

Detection (D) of FC/FM

ve

Occurance (O) of FC
me

Severity (S) of FE
Status:
Serial numnber #

special feature

Occurance (O)
nt 2. Function of the

Detection (D)
1. Function of Process (Untouched,

Severity (s)
1. Process Item, Process Step and 3. Function of the 1. Failure Effects (FE)
His 2. Process Step, Station Item, System, Current Current Detection Target under Action Taken
System, Subsystem, 3. Process Work Product Process Work to the Next Higher 2. Failure Mode (FM) of the 3. Failure Cause (FC) of Completion

AP

AP
tor No. and Name of the Subsystem, Part Prevention Controls of FC or Prevention Action Detection Action Responsibile Person Completion on consideration, with Pointer to Remarks
Part Element or Name Element - 4M Type Characteristics Element and Process Level Element and/or Focus Element the Next Lower Element Date
y Focus Element Element or Name of Controls of FC FM date in progress, Evidence
of the Process (Quantity value is Characteristics End user or Characteristics
the Process completed,
optional)
discarded)

1 B123 Assy line Block Building Machine Plant: Assembly of Assembles the Your plant: Width between inner Press tool Wear(one Tool life Mechanical None. Electrical poke S.Sudhakar 5/1/2021 Under Pending pending pending
(operation no. 30) To assemble the bush and inner Inner plate unable to seat in plates is low. side high and one monitoring is poke yoke at yoke to be (Manufacturing) consideartion
child parts and plates for making through fork the sprocket of side low) available and the end of made available
make a complete a Block as per stick CDM checking 2. Machine loading to be updated chute track is for detecting
chain. design and punches the equipment (Setting tool crack every avaialble to the width
Ship to plant: requirements. bush in to the Customer: Noise formation). month(FRM/N detect. between inner
To support the plates for making and vibration PD/23TL) plates(By using
primary function the Block. issue 2. Operator 2. CDM sensor based
of the vehicle. End user: 8 training and 4 checking 5 M automatic
End user: Degradation of setup sprocket contraol
Smoother primary function approval available at system).
transmission of for(PIR) the final
power and safre avaialble for station.
driving of all product
vehicle. and Process
parameters.