International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 3, Issue 5, May 2013)
PFMEA (Product Failure Mode Effect Analysis) of Air-Duct
Manufacturing Process to Improve Product Quality
Parikshit K patel1, Prof. Vidya Nair2, Ashish Patel3
1,2
Department of Production Engineering, L.D.R.P.-I.T.R., Gandhinagar, Gujarat
3
Department of mechanical engineering –Lit-valsad
Abstract--Manufacturing defects or errors are always the
key concerns of any manufacturing industry. The success of
any organization depends on the quality of product especially
right product produced. This work is to be done in small blow
moulding company, which manufactures the Air duct for
automobile air conditioners. The initial research shows the
past trends of rejection is between 8-9% which includes
human error in material removal, wrong fitting of clamp,
molding defects, etc. the need is to reduce that to compete in
highest competitive market and to continuous satisfaction of
customer. One of the successful tool for finding the failure
mode and its effect in manufacturing process is PFMEA
(Product failure mode effect analysis). By PFMEA we can find
out how critical the process is and we can take action to
reduce the failure in product and improve the manufacturing
process.
After the complete study of the manufacturing process and
production data – failure causes, failure rate, & other relevant
data etc, FMEA discovered the weak processes in the form of
higher risk priority number in the manufacturing of product,
which required reducing by identifying and implementing
mitigation actions and this will improve the process and
product quality & productivity. After execution of process
FMEA for center duct of air conditioning product, it is
identified that major area of failure of center duct during
manufacturing are as follows:
1. De-flashing during manual process
2. Moulding defects left out during inspection
Hence it provided the potential failures of the product so
preventive steps can be taken to improve quality of product
and productivity.
Keywords-- Quality improvement, FMEA, PFMEA,
Automotive AC air duct, Blow moulding
I. INTRODUCTION
In the recent years intensifying competition in the
international economy caused a major change in approach
to quality management. The quality action should therefore
include its reach the whole product life cycle, starting from
customer identification requirements and expectations, by
the customer’s service.
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An important factor in the functioning of company shall
take appropriate selection constant improvement strategies
of processes, where special emphasis is put on preventing
strategy. The prevention strategy replaced detection
strategy; new strategy indicates shifting the focus on the
functions and activities relating to improving each element
and operation broader process. In the present time we have
techniques, tools and methods which support such
approach to the quality. Thanks to Their implementation in
the organization following minimizing costs, eliminate
defects and thus more monitoring and improving the
quality operations in processes.
Based on defect prevention is analysis and monitoring of
each activity in the process and implementation at each
stage of the process and each step operations tests and
safeguards protecting against appearance of a problem.
Collection of information on emerging deficiencies and
prevent them is a much more efficient way of improving
quality than the standard quality control. Observations of
the current problems arising in processes can be their
causes demonstrate.
1.1 Importance of FMEA in quality enhancement
Traditionally, reliability has been achieved through
extensive testing and use of techniques such as
probabilistic reliability modeling. These are techniques
done in the late stages of development. The challenge is to
design in quality and reliability early in the development
cycle. Therefore engineers introduced Failure Modes and
Effects Analysis (FMEA). FMEA is a methodology for
analyzing potential reliability problems early in the
development cycle where it is easier to take actions to
overcome these issues, thereby enhancing reliability
through design. FMEA is used to identify potential failure
modes, determine their effect on the operation of the
product, and identify actions to mitigate the failures. A
crucial step is anticipating what might go wrong with a
product. While anticipating every failure mode is not
possible, the development team should formulate as
extensive a list of potential failure modes as possible.
 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 3, Issue 5, May 2013)
The early and consistent use of FMEA in the design
process allows the engineer to design out failures and
produce reliable, safe, and customer pleasing products.
FMEA does also capture historical information for use in
future product improvement. A subject of research is
automotive air conditioning system air duct products of
company deals with OEM. Production of those air ducts is
done according to different technical requests and standards
of auto industry. Application of FMEA in manufacturing
process of the auto air conditioning side air ducts is done,
potential failures are identified and pre measures are
defined for problems overcoming and quality and lifetime
of systems increase.
1.2 Importance of automotive HVAC air management &
role of FMEA in its manufacturing:
Fig.1 AITOMOTIVE AIR_DUCT
HVAC systems use an air distribution or duct system to
circulate heated and/or cooled air to the entire passenger
compartment. Properly designed duct systems can maintain
uniform temperatures throughout the car passenger
compartment, efficiently and quietly.
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The efficiency of air distribution systems has been found
to be 60-75% or less in many cars because of insufficient
and/or poorly installed duct insulation and leaks in the duct
system and manufacturing defects of ducts. Properly
designed and installed duct systems can have efficiencies
of 80% or more for little or no additional cost, potentially
saving car owner a $50-100 or more per year in heating and
cooling costs. Duct systems that leak and/or do not
distribute air properly throughout the car compartment may
make some portion concentrated in nature i.e., too hot and
others too cold. Leaky and unbalanced duct systems may
force conditioned air outside and unconditioned air into the
car compartment. This increases heating and cooling costs
in context of fuel efficiency and may also draw humidity,
dust, mold spores, and other contaminants into a
compartment from the atmosphere as well as from engine
compartment In extreme cases, poorly designed and
installed duct systems can induce back drafting—spillage
of waste heat from the engine compartment to the
passenger compartment.
All the above stated loop holes can be overcome by
controlling manufacturing process systematically through
Failure mode and effects analysis prior to that we have to
carried out various process study and findings of faults and
in later stage we have to carried out FMEA trials.
1.3 Manufacturing process study:
Company is manufacturing air conditioning ducts for
passenger car, the whole duct is comprise of three sub
parts, named as center duct, side duct LH & RH. After
manufacturing of individual parts they get assembled and
then whole product can be supplied to the OEM customer.
Sometime OEM customer may order individual parts as
well. Here we have studied manufacturing process and
conducted FMEA for center duct only.
The Fig 2. is the process flow diagram for center duct
manufacturing.
 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 3, Issue 5, May 2013)

FIG 2. PROCESS FLOW DIAGRAM

Implementation of FMEA starts with the FMEA FMEA sheet. Standard FMEA sheet developed by IATF
Planning and Cross Functional Team Creation for FMEA – (International Automotive Task Force) is used and is as
Development and then to the Evaluation of the results. below in Table 01.
After preparation of team and planning, next step is to
detailed study of manufacturing process and identification
of each process step and documentation of the same in
Table 1
FMEA SHEET

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 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 3, Issue 5, May 2013)
1.4 Implementation method for FMEA
Then identification of potential failure modes and their
effects for each process steps, always input of CFT is very
essential to have failure effect from all angles. After that
ranking method is used to priories them based on severity,
occurrence and detection method as follows:
Severity:
Severity is an assessment of the seriousness of the effect
and refers directly to the potential failure mode being
studied. The Customer in process FMEA is both the
internal and where appropriate, external Customer. The
severity ranking is also an estimate of how difficult it will
be for the subsequent operations to be carried out to its
specification in Performance, Cost, and Time. The Ranking
and suggested criteria are based on IATF manual of
FMEA version 3. A common industry standard scale uses 1
to represent no effect and 10 to indicate very severe with
failure affecting system operation and safety without
warning.
Causes of failure mode :
Identify the causes for each failure mode. A failure cause
is defined as a design weakness that may result in a
failure. The potential causes for each failure mode should
be identified and documented. The causes should be listed
in technical terms and not in terms of symptoms.
Examples of potential causes include improper torque
applied, Improper operating conditions, too much solvent,
improper alignment, excessive voltage etc.
Occurrence :
The Occurrence is the assessment of the probability that
the specific cause of the Failure mode will occur. A
numerical weight should be assigned to each cause that
indicates how likely that cause is (probability of the cause
occurring).
For that failure history is helpful in increasing the truth
of the probability. Therefore historical data stored in
databases can be used and questions like the following are
very helpful to solve this problem.
• What statistical data is available from previous or
similar process designs?
• Is the process a repeat of a previous design, or have
there been some changes?
• Is the process design completely new?
• Has the environment in which the process is to
operate changeable?
• Have mathematical or engineering studies been used
to predict failure?
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A common industry standard scale uses 1 to represent
unlikely and 10 to indicate inevitable. The Ranking and
suggested criteria are based on IATF manual of FMEA
version 3.
Detection:
Here we have to distinguish between two types of
detection. On one hand we have to identify Current
Controls (design or process). Current Controls (design or
process) are the mechanisms that prevent the cause of the
failure mode from occurring or which detect the failure
before it reaches the Customer. The engineer should now
identify testing, analysis, monitoring, and other techniques
that can or have been used on the same or similar
products/processes to detect failures.
The other thing is to assess the probability that the
proposed process controls will detect a potential cause of
failure or a process weakness. Assume the failure has
occurred and then assess the ability of the Controls to
prevent shipment of the part with that defect. Low
Occurrence does not mean Low Detection - the Control
should detect the Low Occurrence. The Ranking and
suggested criteria are based on IATF manual of FMEA
version 3.
Risk Priority Numbers (RPN) :
The Risk Priority Number is a mathematical product of
the numerical everity, Probability, and Detection ratings:
RPN =(Severity) x (Probability) x (Detection)
The RPN is used to prioritize items than require
additional quality planning or action.
Actions :
Determine Recommended Action(s) to address potential
failures that have a high RPN. These actions could include
specifi c inspection, testing or quality procedures; selection
of different components or materials; de-rating; limiting
environmental stresses or operating range; redesign of the
item to avoid the failure mode; monitoring mechanisms;
performing preventative maintenance; and inclusion of
back-up systems or redundancy.
After that we have to assign Responsibility and a Target
Completion Date for these actions.
1.5 Description of the product/process function of Center
duct
Processes that are needed for the manufacturing of the
center duct can be described as follows: -
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Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 3, Issue 5, May 2013)
Receiving the raw material: - In this process, the raw
material is received from the supplier. Also, the inspection
process should be carried out to decide that the raw
material received is as per invoice.
Storage of raw material: - This is another crucial step, as
it is a part of inventory management.
Blow material of ducts: -The center duct is formed in
this process from the raw material supplied, by the process
of blow molding.
De-flashing:- The process is used to remove excess
molding compound, flash, or resin bleed from the body of a
molded plastic center and the leads.
The excess compound might be present as a normal
characteristic of the mold interface or due to imperfections
in the mold, such as wear. In-process/online inspection: in
this inspection process the molded or the dimensional
defect can be kept a check on.
Hole-punching operation: - Holes are punched in to the
mold in this operation. Two things should be taken care of
while doing this operation.
1. Hole punching location.
2. Hole punch size
Storage of the molded parts: - in this operation the
molded parts are stored, till the assembly operation.

1.6 PFMEA for center duct

Process Function C D
S l Potential cause(s) Current Process Current Process e R
Potential Failure Potential Effect(s) of Oc
Sr No e a / Mechanism(s) of controls controls t P
Mode Failure cur
v s Failure Prevention Detection e N
Requirements s c
Next Operation - Difficult to
process the material Visual inspection on
Assly - Part get rejected in the the bags as per the
Raw material not Wrong material
assly. 7 1 -- invoice details while 6 42
as per invoice supply
Customer - Fit and function unloading the
issues at customer end. material
End Customer - Field failure
Next Operation - Difficult to
process the material Visual inspection on
Assly - Part get rejected in the the bags as per the
Raw material not raw material
assly. 7 Wrong grade supply 1 invoice details while 6 42
as per specification specification sheet
Customer - Fit and function unloading the
issues at customer end. material
End Customer - Field failure
Receiving inspection of Next Operation - Difficult to
10
raw material process the material Visual inspection on
Raw material Lot no. / batch no. &
Assly - Part get rejected in the the bags as per the
without grade not mentioned
assly. 7 1 -- invoice details while 6 42
identification and on the raw material
Customer - Fit and function unloading the
traceability bags.
issues at customer end. material
End Customer - Field failure

Next Operation - Difficult to A) Incoming

process the material inspection of the raw
Mixture of coarse &
Assly - Part get rejected in material
Contaminated raw fine granules / foreign
due to poor aesthetics. 4 3 -- B) Inspection during 4 48
material particles / moisture in
Customer - Part get rejected the material usage
the raw material.
due to poor aesthetics. C) Part inspection
End Customer - Dissatisfaction after moulding.

Next Operation - Difficult to Raw material bags

handle the material Improper loading of checked during
Damaged bags Assly - -- 5 the material / tranist 3 -- unloading at the time 4 60
Customer - -- damage of receipt for
Storage of raw End Customer - -- damages.
20
material Next Operation - Difficult to
Supplier end Raw material bags
process the material
improper loading / checked during
Wet bags Assly - -- 5 2 -- 4 40
Material not coverd unloading at the time
Customer - --
during transit. of receipt.
End Customer - --

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Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 3, Issue 5, May 2013)
Next Operation - Part may
reject / poor appearance.
Assly - Difficulty in assly with High blow speed / First piece approval
Flashes / Parting Standard Process
the mating part. 4 Low holding time and 4 and inprocess 4 64
line Flashes Parameter Sheet
Customer - Part rejected due pressure. inspection sheet.
to poor apperance.
End Customer - Dissatisfaction

Next Operation - Part get

reject / poor appearance.
Blow speed low /
Assly - Difficulty in assly with First piece approval
Short Moulding / Barrel temperature Standard Process
the mating part. 4 4 and inprocess 4 64
Fill low / Air pressure low Parameter Sheet
Customer - Part rejected due inspection sheet.
/ Parision short
to poor apperance.
End Customer - Dissatisfaction
Blow moulding of
30
centre duct
Next Operation - Part get 1) Operator
reject / fitment issues. awareness and
Wrong core & punch
Part weight less or Assly - Part get reject / fitment Standard Process training.
5 size / less or more 3 4 60
more issues. Parameter Sheet 2) First piece
parision length.
Customer - Part get rejected. approval and
End Customer - Dissatisfaction inprocess inspection.

1) First piece
Next Operation - Part poor
approval and
appearance.
Water leakage in the inprocess inspection
Water mark on the Assly - Part poor appearance. Standard Process
3 tool / Chiller temp sheet. 2) 0
part Customer - Part poor Parameter Sheet
too low Tool preventive
appearance.
maintenance plan as
End Customer - Dissatisfaction
per checklist.

Next Operation - Part get

Excessive / less reject / fitment issues / poor 1) Operator
deflashing of the appearance. Unskilled operators / awareness and
40 Deflashing of the part parts along parting Assly - Part get reject / fitment 5 Excessive or less 3 -- training. 4 60
line / Flashes in the issues / poor appearance. deflashing 2) Defective sample
fitment areas. Customer - Part get rejected. display.
End Customer - Dissatisfaction

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Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 3, Issue 5, May 2013)

Next Operation - Part get

reject / fitment issues / poor 1) Standard Process 1) Operator
Moulding /
appearance. Unskilled operators / Parameter Sheet awareness and
Online / Inprocess Dimentional
50 Assly - Part get reject / fitment 5 NA Excessive or less 3 2) First piece approval training. 4 60
inspection defects in the
issues / poor appearance. deflashing and inprocess 2) Defective sample
component
Customer - Part get rejected. inspection. display.
End Customer - Dissatisfaction

Next Operation - Part get 1) Operator

reject / fitment issues. awareness and
Hole punching Assly - Part get reject / fitment Hole location marked in training.
5 Unskilled operators 4 4 80
location wrong. issues. the tool. 2) First piece
Customer - Part get rejected. approval and
End Customer - Dissatisfaction inprocess inspection.
Hole punching
60
operation.
Next Operation - Part get 1) Operator
reject / fitment issues. awareness and
Hole punching size Assly - Part get reject / fitment Punch wear out / training.
5 2 -- 5 50
wrong. issues. wrong punch used. 2) First piece
Customer - Part get rejected. approval and
End Customer - Dissatisfaction inprocess inspection.

Next Operation - Part get

1) Operator
reject / fitment issues.
awareness and
Improper storage / Assly - Part get reject / fitment Part storage in poor
70 Storage of parts 4 NA 1 -- training. 5 20
handling issues. condition.
2) Part storage and
Customer - Part get rejected.
handling instructions.
End Customer - Dissatisfaction

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Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 3, Issue 5, May 2013)

Next Operation - Difficult to fit

side duct
Improper heating Assly - Difficult to assemble Manual heating of
6 Unskilled operator 2 --- 5 60
of centre duct the duct. the centre duct.
Customer - Part get rejected.
End Customer - Field failure.
80 Heating of centre duct
Next Operation - Difficult to
assemble the ducts.
Assly - Part get rejected in the
Moulding defects
assly. 6 Unskilled operator 3 --- --- 8 144
in the ducts.
Customer - Fit and function
issues at customer end.
End Customer - Field failure
Next Operation - Part get
rejeted. Operator training /
Side duct fixing in Assly - Part get rejected. inprocess inspection
6 Unskilled operator 2 --- 5 60
wrong direction Customer - Fitment issues at / inspection on
customer end. checking fixture.
Fixing of side ducts & End Customer - --
90 centre duct assembly
Next Operation - Improper
inspection.
fitment of part.
Side duct foam
Assly - Improper fitment of
visible from centre 5 Unskilled operator 3 --- Operator awareness 7 105
part.
duct joint area.
Customer - Part get rejected.
End Customer - --

Next Operation - Part get

rejected. .
Defective centre Operator awareness
Assly - Part get rejected. 6 Unskilled operator 5 --- 8 240
duct assembly / Visual instruction
Customer - Part get rejected.
End Customer - ---
Packaging of centre
100
duct assembly. Next Operation - Part get
rejected.
Operator awareness
Non standard Assly - ---
5 Unskilled operator 1 --- / Packaging 6 30
packaging Customer - Part get rejected /
instruction.
Dissatisfaction
End Customer - ---

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 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 3, Issue 5, May 2013)
1.7 Conclusion of PFMEA
After Successful Process of PFMEA following are the recommendation are given to Existed Process

Process Function
Sr No Requirements Potential Failure Mode Recommended Action(s)

Flashes / Parting line Flashes

Parameter setting panel to be
1 Blow moulding of centre duct modified to stop alteration
Short Moulding / Fill without access rights
Part weight less or more

Excessive / less deflashing of

Cutting Fixture is to
2 Deflashing of the part the parts along parting line /
developed and implemented
Flashes in the fitment areas.

Moulding / Dimentional Go/No Go Fixture to be

3 Online / Inprocess inspection
defects in the component developed and implemented

Defective centre duct assembly

Side duct LH / RH fitment on Inspection fixture to be

4 Pre dispatch inspection wrong direction developed and Implemented

Missing component (Foam /

mounting bracket)

All Above Potential Failures will be solved by Error Proofing (Poka Yoke) and overall quality can be enh anced
REFERENCE
[1] Potential Failure Mode & Effects Analysis - AIAG manual, fourth
edition, effective June 1st 2006 copyright DaimlerChrysler
Corporation, Ford Motor Company, General Motors Corporation.
[2] Production part approval process - AIAG manual, fourth edition,
effective June 1st 2006 copyright DaimlerChrysler Corporation,
Ford Motor Company, General Motors Corporation.
[3] Air Distribution System Design, U.S Department of energy
proceedings pp number 5- 6.
[4] White paper on Strategies and Tips for Maximizing Failure Mode &
Effect Analysis in Your Organization- prepared and published by the
American society for risk management, published July 2002.
[5] Project Risk Management Using the Project Risk FMEA, Thomas A.
Carbone, Fairchild emiconductor Corporation, Donald D. Tippett,
The University of Alabama in Huntsville, Engineering Management
Journal Vol. 16 No. 4 December 2004.

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