Customer: BENCHMARK FMEA number:

Part number: AMT0008908KU

Process / Product Prepare by: Muhamad Ammar
Revision: Failure Modes and Effects Analysis Approve By:

Process description: Bracket KU

(FMEA) FMEA Date:

Severi Occu Detect S O D

Potentioal Failure ty
products/process Potentioal Failure Modes (S) Potential causes of Failure rance Current Process Controls Prevention ion (RPN) Corrective action owner start date verify date E C E
effects (D) V C T
(O)

Customer not Prepare setup sheet to provide training,

satisfied , Effect next Setup programme error, method of provide training how to use measuring 1.Provide training & maintanance schedule
1 (Sham)
process, High material inspection incorrect, Machine tools, Machine maintanance checklist 2. prepare setup sheet
Laser Cut Dimension Out of Spec 8 10 6 480 3 (Ammar)
cost, Lost our performance, Drawing error, wrong (weekly & monthly), individual process 3. prepare individual process drawing
2,4 (Faiz)
productivity, Labour setup, Material thickness drawing, Material thickness base on 4. do labelling & marking
cost labelling & marking

Customer not
satisfied , Effect next
process, High material
Part Damage cost, Lost our 8 wrong handling, Programmer know
productivity, Labour
cost, Damage the Laser
Nozzle, Shutter
Prepare setup sheet to provide training,
1.Provide training for measuring tools. 1. (Syafiq)
Wrong Setup, Machine perfomance, provide training how to use measuring
2.Prepare setup sheet 3.Prepare 2.(Sham)
6 tools, Machine mattainance checklist 8 384
carrier bin for storage. 4.Machine 3.(Hanjie)
how (weekly & monthly), storage inside carrier
maintanence schedule. 4.(Faiz)
bin

1.Provide training for parts handling.

Customer not Handling, Machine 5s, No proper Storage inside carrier bin, perform weekly
Part Scratches 3 10 8 240 2.Prepare maintanence schedule 1, 2. (Sham)
satisfied carrier bin, Incoming maintainance
3.Prepare carrier bin 3.(Hanjie)

Part Warping,
Over Heat Dimension Out, 3 Programmer know how 6 Basic Exam/ WI for software 9 162 N/A
Part Twist

Part Damage, High

Material Cost,
Lost our productivity
Programme Error 8 Programmer know how 6 Basic Exam/ WI for software 9 432 1. Provide training for programmer 1. (Amada)
& Labour cost,
Tooling damage,
Customer not satisfied

Material wasted, Handling, Machine clamper sensor not

function Fix 2 person carry heavy parts, weekly
Raw Material misalign Shutter damage, 3 6 8 144 N/A
maintainance, prepare WI
No proper cutting
Material wasted,
Qurantine the parts and send for buyoff/ 1.Provide carrier bin 1.(Hanjie)
No Proper Cut Productivity effect & 8 Power failure, Programmer know how 6 8 384
basic exam (WI for software) 2.Provide WI for software 2. (Sham)
Labour cost

Next process effect, Wrong Nozzle use, Machine condition Prepare setup sheet to provide training,
Burr 3 6 8 144 N/A
cosmatic issue & perfomance Machine maintainance weekly & monthly

Material wasted,
Machine perfomance, programmer Machine maintainance weekly & monthly,
Over Travel Productivity effect & 2 6 5 60 N/A
know how basic exam (internal or external training)
Labour cost

Material waste,
1.Provide thickness gauge for measurement.
Wrong Material - Material Customer not Do measurement before load the material, 1.(Sham)
8 No proper label,marking, storage 6 6 288
type satisfied, Do a label markin 2. (Hanjie)
2. Provide label marking.
Effect next process

Part damage,
Customer not Power failure, programming error, Qurantine the parts and send for buyoff, 1.Provide carrier bin 1.(Hanjie)
Over Cut 8 6 8 384
satisfied, machine alarm, programmer know how basic exam (internal or external training) 2.Provide training for programmer 2.(Amada)
Material & Labour cost

Part damage,
Material & Labour
cost,
Machine damage, Technician know how, No proper setup Prepare setup sheet WI how to operate the
Wrong Setup Machine 5 6 8 240 1.Provide setup sheet & WI 1.(Sham)
Hardburr, sheet & W machine
Productivity effect,
Laser Cut Nozzle
damage

Delay our shipment

schedule Prepare Master file and keep at the
Programme missing 3 No proper storage & filling 6 5 90
, Labour cost, machine
Machine cost

KWPG2-EN-FRM-009 REV C
 Dimension Out,
Customer not satisfied, 1. Prepare Golden sample 1,4.(Faiz)
Material waste, Effect 1. Human error 2. No proper jig 3. No 1. Golden sample 2. Provide training 3. Use a 2. WI 2. (Sham)
Buffing Over buff
next process, Machine &
4
proper tools use 4. No proper method
8
jig 4. Have a WI
8 256 3. Design Jig 3.(Ammar)
labour cost, effect 4. Jig maintanance schedule
productivity

1. Prepare Golden sample 1,4.(Faiz)

Effect next process,
1. Human error 2. No proper jig 3. No 1. Golden sample 2. Provide training 3. Use a 2. WI 2. (Sham)
Micro joint no remove injuring, dimension out, 9
proper tools use 4. No proper method
9
jig 4. Have a WI
8 648 3. Design Jig
effect assy process, 3.(Ammar)
4. Jig maintanance schedule

Customer not satisfied , 1. Prepare Golden sample 1,4.(Faiz)

Effect next process, High 1.Over buff 2. No proper jig, 3. No proper 1. Golden sample 2. Provide training 3. Use a 2. WI 2. (Sham)
Warping
material cost, Lost our
8
tools 4. No proper method
6
jig 4. Have a WI
8 384 3. Design Jig 3.(Ammar)
productivity, Labour cost, 4. Jig maintanance schedule

Customer not satisfied , 1. Prepare Golden sample 1,4.(Faiz)

Effect next process, High 1. Golden sample 2. Provide training 3. Use a 2. WI 2. (Sham)
Dented
material cost, Lost our
4 1. No 5s 2. Handling 3. No proper jig & bin 8
jig 4. Have a WI 5. Have proper bin
8 256 3. Design Jig 3.(Ammar)
productivity, Labour cost, 4. Jig maintanance schedule

Customer not satisfied , 1. Prepare Golden sample 1,4.(Faiz)

Effect next process, High 1. Handling 2. No Proper jig 3. No proper 1. Golden sample 2. Provide training 3. Use a 2. WI 2. (Sham)
Part Damage
material cost, Lost our
8
tools use 4. No proper method
7
jig 4. Have a WI 5. Have proper bin
8 448 3. Design Jig 3.(Ammar)
productivity, Labour cost, 4. Jig maintanance schedule

Prepare setup sheet to provide training,

Customer not satisfied , provide training how to use measuring tools,
method of inspection incorrect, Machine
Effect next process, High Machine mattainance checklist (weekly &
Bending Dimension Out of Spec
material cost, Lost our
8 performance, Drawing error, wrong setup, 10
monthly), individual process drawing, Material
7 560 Invidual process drawing Ammar
Material thickness, loading & unloading
productivity, Labour cost thickness base on labelling & marking,
provide inspection training

Over press & under press, material

Material thickness & tooling checklist, have
Angle Out Wrong tooling 6 thickness, not suitable tools, not proper 10
proper bin
5 300 Inspection Checklist Syafiq
carrier bin
Bending Mark Cosmatic effect, 4 Over press, sharp edge, v-die, 9 Visual inspection, tooling checklist 5 180 Inspection Checklist Syafiq

1. No WI 2. No proper training 3. No proper

Wrong Orientation Effect next process, 8
marking 4. Drawing error
8 1. WI 2. Prepare jig 3. drawing checklist 5 320 Drawing checlist - Ammar

1. Provide training 2. drawing checklist 3.

Bending flange not even
1. Not proper v-die use 2. Drawing error 3.
Dimension out, 6
Micro joint 4. Burr 5. Stopper wear and tear
7 Visual inspection 4. Maintanance checklist 5 210 Drawing checlist - Ammar
schedule (weekly & monthly)

Effect next process,

Power failure, machine alarm, no follow Qurantine the parts and send for buyoff, refer
Material waste,
Skip Process
Productivity & Labour
8 bending sequences, drawing no indicate 7 golden sample & 3D drawing, update process 5 280 Drawing checlist - Ammar
bending sequences, drawing
cost effect,

Material Waste,
Wrong setting Productivity & Labour 8 No Setup sheet, No WI, 6 Prepare setup sheet & WI 5 240 Tooling Checklist Syafiq
cost effect

Part damage, Material

Wrong tools
waste
8 No Setup sheet, No WI, 6 Prepare setup sheet & WI 4 192 Tooling Checklist Syafiq

Customer not satisfied ,

Chips stucked at v-die and punch,
Dented High Lost our 4
handling, no proper bin,
10 Machine 5s training, proper storage 4 160 Training record Syafiq
productivity, Labour cost,

Customer not satisfied ,

Chips stucked at v-die and punch,
Part Scratches High Lost our 4
handling, no proper bin,
10 Machine 5s training, proper storage 4 160 Training record Sham
productivity, Labour cost,

Customer not satisfied ,

High material cost, Lost
Part Damage
our productivity, Labour
8 Wrong setup, handling, 6 Setup sheet & WI 4 192 Training record Sham
cost,

Loading error Part damage 8 Human error 9 Provide training , WI 9 648 WI Inspection Sham

Compare customer drawing with 3D drawing

Drawing Error Dimension out `8 Human error 6
to verify
4 192 Drawing refer Ammar

F-QA-079-A

KWPG2-EN-FRM-009 REV C
R
P
N

KWPG2-EN-FRM-009 REV C
KWPG2-EN-FRM-009 REV C
 Severity

influences Criterion: Severity definition grade

There will be no substantial impact on the product and subsequent operations and processes,
Very low 1
and customers will hardly notice it.
It has limited impact on the current process, will not affect the subsequent process, and has
low 2
no impact on customers.
May cause rework of current process. 3

medium Causes customer dissatisfaction. 4

The customer requested corrective action. 5

Customers have noticed a decrease in quality. 6

high The product does not meet the standard requirements and cannot be used. 7

The production line is severely interrupted, and all products may be scrapped. Major
8
functions fail. Customers are very dissatisfied.

Very high Potential security risks or violations of laws and regulations. 9

Security issues or violations of laws and regulations. 10

Page 5 KWPG2-EN-FRM-009 REV C

 Occurance

Approximate process
Incidence Probable failure rate fraction
capacity Cpk
Hardly happen: Failure is unlikely. No
failures ever associated with almost £ 1 in 108 ³ 2.0 1
identical processes

Very low: Only isolated failures associated

1 in 106 ³ 1.67 2
with almost identical processes

Low: Isolated failures associated with

1 in 20,000 ³ 1.33 3
similar processes

Medium: Process in Statistical Control but

1 in 3,000 ³ 1.0 4
with isolated failures

Previous processes have experienced

occasional failures or out-of -control 1 in 1000 < 1.0 5
conditions
1 in 400 6

High: Processes not in Statistical Control. 1 in 40 7

Similar processes have experienced

1 in 20 8
problems
Very high: Failure is almost inevitable 1 in 8 9
³ 1 in 2 10

Page 6 KWPG2-EN-FRM-009 REV C

 Detection

Possibility of nonconformities found with current control

Discovery rate Missed detection possibility DPPM Fraction
methods.

Very High Defects are automatically found in the process 1 in 10,000 100 1
Very High Control will almost certainly find defects 1 in 5000 200 2
High There is a high chance that control will find defects 1 in 2000 500 3
1 in 1000 1,000 4
Moderate Controls may find defects 1 in 500 2,000 5
1 in 200 5,000 6
1 in 100 10,000 7
Low It is also difficult to find defects in control 1 in 50 20,000 8
1 in 20 50,000 9
Very Low Controls will not detect defects 1 in 10 100,000 10

Page 7 KWPG2-EN-FRM-009 REV C

 Fault Tree Analysis

Scraches on class A
surface

Laser maring PEM assembly

Process Process

AND AND

Metal table Operator Operator Metal table

contaction handling handling contaction