Doc.

No FM-ENG-16-04
MTD Industries Sdn. Bhd. Issued Date 28 Jun 2022

PROCESS FAILURE MODE AND EFFECT ANALYSIS Page 1/1

Customer JABIL PFMEA Number FMEA-0111

Part No. 714-A54838-004. PFMEA Date 22 /11/ 2023
Part Name BRKT END STOP ILLON 700 ALLI 6 Revision Part Number A
Project Name VERSA
Team Members Shahibun, Marhan, Wai Hoong, Faz, Kishore, Iman, Zul, Lina, Abu Bakar, Faidzal, Faizal, Hilmi, Izzah
Process LASER CUT,BUFFING, BENDING, STAMP CODE, PACKING.

Prepared by AMIN Approved by MARHAN

Value>100 (Action needed) or (customer specific requirement RPN: 100)

Severity Occurance Detection RPN.SxOxD
Results
Process Description / Potential Failure Potential Effect of Potential Cause (S) Corrective PIC & Date Action
S O Current Controls D RPN Action Priority
Function Mode Failure of Failure Action Due Taken S O D RPN

Material Handling or Store person will checking the material

Wrong material Delayed schedule 7 discrepancies caused 2 Label and Fill up Material Tag during In- 6 84 N/A N/A N/A N/A N/A N/A N/A N/A
by Supplier coming from supplier
Missing material
Store person checking the quantity with
Wrong material Wrong Quantity 6 during ship out from 2 6 72 N/A N/A N/A N/A N/A N/A N/A N/A
D.O
supplier
Wrong material
taking during Use competent store Store person checking the quantity with
Wrong material 6 2 6 72 N/A N/A N/A N/A N/A N/A N/A N/A
transfer to hand and MH only D.O
transportation
Missing material
Store person checking the quantity with
Shortage quantity Delayed schedule 7 during ship out from 2 6 84 N/A N/A N/A N/A N/A N/A N/A N/A
D.O
supplier
Not achieved
Dented , Scratches Wrong processing
cosmetic 4 3 Appearance check and visual Inspection 7 84 N/A N/A N/A N/A N/A N/A N/A N/A
and Damage parameters
requirement
Raw Material Material Handling or
Dented , Scratches Appearance check during In-Coming
Receiving Delayed schedule 7 discrepancies caused 2 7 98 N/A N/A N/A N/A N/A N/A N/A N/A
and Damage Inspection
by Supplier
Premature failure
Material storage Appearance check during In-Coming
Surface Rust of test results for 6 2 7 84 N/A N/A N/A N/A N/A N/A N/A N/A
(WIP) Inspection
corrosion
Not achieved
Material Handling or
cosmetic and Appearance check during In-Coming
warpage 4 discrepancies caused 2 7 56 N/A N/A N/A N/A N/A N/A N/A N/A
functional Inspection
by Supplier
requirement
Not achieved
Material Handling or
Surface cosmetic and Appearance check during In-Coming
4 discrepancies caused 2 7 56 N/A N/A N/A N/A N/A N/A N/A N/A
Roughness functional Inspection
by Supplier
requirement
Not achieved
Material Handling or
cosmetic and Appearance check during In-Coming
Un-even Surface 4 discrepancies caused 2 7 56 N/A N/A N/A N/A N/A N/A N/A N/A
functional Inspection
by Supplier
requirement
Not achieved
Dented , Scratches Wrong processing Appearance check during In-Coming
cosmetic 4 3 7 84 N/A N/A N/A N/A N/A N/A N/A N/A
and Damage parameters Inspection
requirement
Material Handling or
Dented , Scratches Appearance check during In-Coming
Delayed schedule 7 discrepancies caused 2 7 98 N/A N/A N/A N/A N/A N/A N/A N/A
and Damage Inspection
by Supplier
Not achieved Material Handling or
Appearance check during In-Coming
Surface Dented cosmetic 4 discrepancies caused 2 7 56 N/A N/A N/A N/A N/A N/A N/A N/A
Inspection
requirement by Supplier
Not achieved Material Handling or
Appearance check during In-Coming
Surface Scratches cosmetic 4 discrepancies caused 2 7 56 N/A N/A N/A N/A N/A N/A N/A N/A
Inspection
requirement by Supplier
Material Material may crack Inadequate process Measurement during In-Coming
7 4 3 84 N/A N/A N/A N/A N/A N/A N/A N/A
Dimension Out during fabrication control at supplier Inspection
Material Not match during Wrong material Measurement during In-Coming
7 3 3 63 N/A N/A N/A N/A N/A N/A N/A N/A
Dimension Out assemble shipped by Supplier Inspection
Premature failure
In-coming Inspection Material storage Appearance check during In-Coming
Surface Rust of test results for 6 2 7 84 N/A N/A N/A N/A N/A N/A N/A N/A
(WIP) Inspection
corrosion
Not achieved
Material Handling or
cosmetic and Appearance check during In-Coming
Warpage 4 discrepancies caused 2 7 56 N/A N/A N/A N/A N/A N/A N/A N/A
functional Inspection
by Supplier
requirement
Not achieved
Material Handling or
Surface cosmetic and Appearance check during In-Coming
4 discrepancies caused 2 7 56 N/A N/A N/A N/A N/A N/A N/A N/A
Roughness functional Inspection
by Supplier
requirement
Not achieved
cosmetic and Material storage Appearance check during In-Coming
Corrosion 4 2 7 56 N/A N/A N/A N/A N/A N/A N/A N/A
functional (WIP) by Supplier Inspection
requirement

Material Handling or
Wrong type Fill up Material Tag during In-coming
Delayed schedule 7 discrepancies caused 2 4 56 N/A N/A N/A N/A N/A N/A N/A N/A
Material from supplier
by Supplier

Damage of Off set & scrapped Use of wrong

3 2 Parameter control 4 24 N/A N/A N/A N/A N/A N/A N/A N/A
machine part produced program

Laser Cut Setup

Not achieved
Wrong processing
Cutting Damage cosmetic 3 2 Parameter control 4 24 N/A N/A N/A N/A N/A N/A N/A N/A
parameters
requirement

Not achieved
Cutting Laser Wrong processing
cosmetic 4 3 Save and record the Parameter control 3 36 N/A N/A N/A N/A N/A N/A N/A N/A
Damage parameters
requirement
Dimension out of
Delayed schedule 6 Wrong profile 3 Use process drawing as reference 4 72 N/A N/A N/A N/A N/A N/A N/A N/A
Spec
Dimension out of
Wrong Profile 7 Wrong program 3 Save and record the Parameter control 3 63 N/A N/A N/A N/A N/A N/A N/A N/A
Spec
Not achieved
Dimension out of Wrong processing
functional 6 3 Save and record the Parameter control 3 54 N/A N/A N/A N/A N/A N/A N/A N/A
Spec parameters
requirement
Not achieved
Speed Pressure
High Burr functional 4 5 Save and record the Parameter control 3 60 N/A N/A N/A N/A N/A N/A N/A N/A
control
requirement
Not achieved
Laser Cut Process Wrong processing Overlook the Setting Review before start up the program and
functional 5 3 3 45 N/A N/A N/A N/A N/A N/A N/A N/A
parameters during Program Use process drawing as reference
requirement
Not achieved
Wrong handling
Missing Process functional 3 4 Check against with Process drawing 4 48 N/A N/A N/A N/A N/A N/A N/A N/A
method
requirement
Not achieved
Review Process Drawing as reference
Missing Profile functional 6 Wrong program 3 3 54 N/A N/A N/A N/A N/A N/A N/A N/A
before start up the program
requirement
Overlook the Setting
Wrong program Delayed schedule 6 3 Save and record the Parameter control 3 54 N/A N/A N/A N/A N/A N/A N/A N/A
during Program
Not achieved
Speed Pressure
Burn Marking cosmetic 4 3 Appearance check and visual Inspection 6 72 N/A N/A N/A N/A N/A N/A N/A N/A
control
requirement
 Not achieved
Lack of Dimension Wrong processing
functional 6 4 Check against Process drawing 4 96 N/A N/A N/A N/A N/A N/A N/A N/A
of specification parameters
requirement
Not achieved
Check against Work instruction and Visual
Missing Process customer drawing 6 Not follow sequence 3 4 72 N/A N/A N/A N/A N/A N/A N/A N/A
inspection
requirement
Not achieved
Wrong processing
Warpage / functional 6 4 Check against Process Control Plan (PCP) 2 48 N/A N/A N/A N/A N/A N/A N/A N/A
checklist
requirement
flatness of the
Not achieved
parts Wrong processing Work Instruction & Checking jig
functional 6 4 2 48 N/A N/A N/A N/A N/A N/A N/A N/A
In-process Inspection checklist (Poka Yoke)
requirement
Not achieved Have been trained on process
Appearance not Wrong method of
functional 7 3 requirement by internal Qualified 2 42 N/A N/A N/A N/A N/A N/A N/A N/A
acceptable handling
requirement Inspector
Wrong checking Dimension out No guideline and Leader will print and check the label Shall
7 2 6 84 N/A N/A N/A N/A N/A N/A N/A N/A
method of specification training verify by Packing Coordinator
Wrong Judgment Process Ability Not understand on Provide Training for
7 2 3 42 N/A N/A N/A N/A N/A N/A N/A N/A
condition Effected requirement requirement

Wrong delivery Wrong entry of

Wrong Label 4 2 Check Label when paste 7 56 N/A N/A N/A N/A N/A N/A N/A N/A
part to customer information

Use suitable
Not achieved Provide
Dimension out of Wrong processing handling Superior &
functional 6 Over buffing 4 Check against with Process drawing 4 96 training and 6 3 4 72
specification parameters method for TBA
requirement WI
run machine
Have assign only qualified operator to
Operator and do not
Not achieved perform the buffing process that
Uneven buffing on understand
cosmetic 4 2 understand customer requirements. 4 32 N/A N/A N/A N/A N/A N/A N/A N/A
product surface customer
requirement Process shall monitor by Supervisor and
requirement
QC.
Not achieved
Under/ over Wrong method of Visual inspection by compare with master
cosmetic 4 4 4 64 N/A N/A N/A N/A N/A N/A N/A N/A
buffing handling sample
requirement
Not achieved
Wrong grid of Wrong method of Visual inspection by compare with master
cosmetic 4 4 4 64 N/A N/A N/A N/A N/A N/A N/A N/A
sand paper use handling sample
requirement
Buffing process
Not achieved
Wrong handling
Deform functional 6 2 Appearance check and visual Inspection 7 84 N/A N/A N/A N/A N/A N/A N/A N/A
method
requirement
Not achieved
Surface cosmetic and Material Handling or
4 2 Appearance check and visual Inspection 7 56 N/A N/A N/A N/A N/A N/A N/A N/A
Roughness functional discrepancies
requirement
Not achieved
cosmetic and Wrong processing
Damage 4 3 Appearance check and visual Inspection 7 84 N/A N/A N/A N/A N/A N/A N/A N/A
functional parameters
requirement
Not achieved
Wrong handling
Line Marking cosmetic 4 2 Appearance check and visual Inspection 7 56 N/A N/A N/A N/A N/A N/A N/A N/A
method
requirement
Not achieved
Wrong method of Visual inspection by compare with master
Wrong direction cosmetic 4 4 2 32 N/A N/A N/A N/A N/A N/A N/A N/A
handling sample
requirement
Not achieved
Lack of Dimension Wrong processing
functional 6 4 Check against Process drawing 4 96 N/A N/A N/A N/A N/A N/A N/A N/A
of specification parameters
requirement
Not achieved
Check against Work instruction and Visual
Missing Process customer drawing 6 Not follow sequence 3 4 72 N/A N/A N/A N/A N/A N/A N/A N/A
inspection
requirement
Not achieved
Wrong processing
functional 6 4 Check against Process Control Plan (PCP) 2 48 N/A N/A N/A N/A N/A N/A N/A N/A
Warpage / checklist
requirement
flatness of the
parts Not achieved
Wrong processing Work Instruction & Checking jig
functional 6 4 2 48 N/A N/A N/A N/A N/A N/A N/A N/A
checklist (Poka Yoke)
requirement
In-process Inspection
Not achieved Have been trained on process
Appearance not Wrong method of
functional 7 3 requirement by internal Qualified 2 42 N/A N/A N/A N/A N/A N/A N/A N/A
acceptable handling
requirement Inspector

Wrong checking Dimension out No guideline and Leader will print and check the label Shall
7 2 6 84 N/A N/A N/A N/A N/A N/A N/A N/A
method of specification training verify by Packing Coordinator

Wrong Judgment Process Ability Not understand on Provide Training for

7 2 3 42 N/A N/A N/A N/A N/A N/A N/A N/A
condition Effected requirement requirement

Wrong delivery Wrong entry of

Wrong Label 4 2 Check Label when paste 7 56 N/A N/A N/A N/A N/A N/A N/A N/A
part to customer information

Damage of Off set & scrapped Use of wrong

3 2 Parameter control 4 24 N/A N/A N/A N/A N/A N/A N/A N/A
machine part produced program
Bending Setup
Not achieved
Wrong processing
Cutting Damage cosmetic 3 2 Parameter control 4 24 N/A N/A N/A N/A N/A N/A N/A N/A
parameters
requirement
Not achieved
Dimension out of Wrong bending
functional 6 4 Use process drawing as reference 2 48 N/A N/A N/A N/A N/A N/A N/A N/A
specification punch used
requirement
Not achieved
Dimension out of Wrong bending die
functional 6 4 Use process drawing as reference 2 48 N/A N/A N/A N/A N/A N/A N/A N/A
specification used
requirement
Not achieved
Not proper handling
Line Marking cosmetic 4 2 Appearance check and visual Inspection 7 56 N/A N/A N/A N/A N/A N/A N/A N/A
method
requirement
Not achieved
Wrong processing
Line Marking cosmetic 7 3 Review before start up the program 4 84 N/A N/A N/A N/A N/A N/A N/A N/A
parameters
requirement
Not achieved
Dirty at die and
Dented cosmetic 4 3 Cleaning part surface before loading 4 48 N/A N/A N/A N/A N/A N/A N/A N/A
punch surface
requirement
Not achieved
Dented cosmetic 7 Punch chip off 2 Review before start up the program 3 42 N/A N/A N/A N/A N/A N/A N/A N/A
requirement

Bending Process Make a Jig

follow correct
direction,
Supervisor Training
Overlook profile Fabricate jig for publish work
Wrong direction Delayed schedule 6 4 Use process drawing as reference 4 96 & 2 Weeks bender and 5 4 3 60
during setting specific part / process intruction and
after notice calibrate jig
process
drawing for
reference

Wrong processing
Bending Slanting Delayed schedule 6 3 Add Laser line mark as per guide line 3 54 N/A N/A N/A N/A N/A N/A N/A N/A
parameters

Not achieved
Not proper handling
Bending Slanting functional 7 4 Add Laser line mark as per guide line 3 84 N/A N/A N/A N/A N/A N/A N/A N/A
method
requirement

Wrong processing
Bending Crack Delayed schedule 6 3 Review before start up the program 3 54 N/A N/A N/A N/A N/A N/A N/A N/A
parameters

Not achieved
Wrong processing
Chemical Trap cosmetic 4 3 Review before start up the program 3 36 N/A N/A N/A N/A N/A N/A N/A N/A
parameters
requirement
 Not achieved
Lack of Dimension Wrong processing
functional 6 4 Check against Process drawing 4 96 N/A N/A N/A N/A N/A N/A N/A N/A
of specification parameters
requirement
Not achieved
Check against Work instruction and Visual
Missing Process customer drawing 6 Not follow sequence 3 4 72 N/A N/A N/A N/A N/A N/A N/A N/A
inspection
requirement
Not achieved
Wrong processing
functional 6 4 Check against Process Control Plan (PCP) 2 48 N/A N/A N/A N/A N/A N/A N/A N/A
Warpage / checklist
requirement
flatness of the
parts Not achieved
Wrong processing Work Instruction & Checking jig
functional 6 4 2 48 N/A N/A N/A N/A N/A N/A N/A N/A
checklist (Poka Yoke)
requirement
In-process Inspection
Not achieved Have been trained on process
Appearance not Wrong method of
functional 7 3 requirement by internal Qualified 2 42 N/A N/A N/A N/A N/A N/A N/A N/A
acceptable handling
requirement Inspector

Wrong checking Dimension out No guideline and Leader will print and check the label Shall
7 2 6 84 N/A N/A N/A N/A N/A N/A N/A N/A
method of specification training verify by Packing Coordinator

Wrong Judgment Process Ability Not understand on Provide Training for

7 2 3 42 N/A N/A N/A N/A N/A N/A N/A N/A
condition Effected requirement requirement

Wrong delivery Wrong entry of

Wrong Label 4 2 Check Label when paste 7 56 N/A N/A N/A N/A N/A N/A N/A N/A
part to customer information

Not achieved
Appearance not Wrong method of
cosmetic 2 2 Visual inspection 7 28 N/A N/A N/A N/A N/A N/A N/A N/A
acceptable handling
requirement
Not achieved
Appearance not Wrong Position of Check against with
Stamp Code Process cosmetic 2 2 4 16 N/A N/A N/A N/A N/A N/A N/A N/A
acceptable stamp code process drawing
requirement
Not achieved Wrong P/N or
Appearance not Check against with
cosmetic 2 Revision of stamp 2 4 16 N/A N/A N/A N/A N/A N/A N/A N/A
acceptable process drawing
requirement code
Not achieved
Lack of Dimension Wrong processing
functional 6 4 Check against Process drawing 4 96 N/A N/A N/A N/A N/A N/A N/A N/A
of specification parameters
requirement
Not achieved
Check against Work instruction and Visual
Missing Process customer drawing 6 Not follow sequence 3 4 72 N/A N/A N/A N/A N/A N/A N/A N/A
inspection
requirement
Not achieved
Wrong processing
Warpage / functional 6 4 Check against Process Control Plan (PCP) 2 48 N/A N/A N/A N/A N/A N/A N/A N/A
checklist
flatness of the requirement
Not achieved
parts Wrong processing Work Instruction & Checking jig
functional 6 4 2 48 N/A N/A N/A N/A N/A N/A N/A N/A
checklist (Poka Yoke)
requirement
In-process Inspection Not achieved Have been trained on process
Appearance not Wrong method of
functional 7 3 requirement by internal Qualified 2 42 N/A N/A N/A N/A N/A N/A N/A N/A
acceptable handling
requirement Inspector

Wrong checking Dimension out No guideline and Leader will print and check the label Shall
7 2 6 84 N/A N/A N/A N/A N/A N/A N/A N/A
method of specification training verify by Packing Coordinator

Wrong Judgment Process Ability Not understand on Provide Training for

7 2 3 42 N/A N/A N/A N/A N/A N/A N/A N/A
condition Effected requirement requirement

Wrong delivery Wrong entry of

Wrong Label 4 2 Check Label when paste 7 56 N/A N/A N/A N/A N/A N/A N/A N/A
part to customer information

Functionality may Wrong processing

Wrong method 6 3 Check against packing standards 4 72 N/A N/A N/A N/A N/A N/A N/A N/A
be affected parameters

Not following
Functionality may
Packaging Damage 6 Packaging 3 Check against Packing Instruction 4 72 N/A N/A N/A N/A N/A N/A N/A N/A
be affected
Instruction
Not following
Functionality may Conduct testing before implementation
Packaging Damage 3 Packaging 2 2 12 N/A N/A N/A N/A N/A N/A N/A N/A
be affected following procedure
Requirement
Not following
Shortage quantity Delay schedule 6 Packaging 3 Check against Packing Instruction 4 72 N/A N/A N/A N/A N/A N/A N/A N/A
Packing Instruction
Checking of labels by operators when
Wrong information Wrong entry of
Wrong label 2 5 pasting and by inspectors during outgoing 4 40 N/A N/A N/A N/A N/A N/A N/A N/A
to customer information
inspection
Operator did not
follow in process
Missing label Customer rejection 4 2 Supervisor and line leader verify 7 56 N/A N/A N/A N/A N/A N/A N/A N/A
inspection
instructions

Wrong Packing No Follow Packing

Part may damage 4 2 Check against Packing Instruction 4 32 N/A N/A N/A N/A N/A N/A N/A N/A
Method Instruction

Not achieved
Lack of Dimension Wrong processing
functional 6 3 Check against Process drawing 4 72 N/A N/A N/A N/A N/A N/A N/A N/A
of specification parameters
requirement
Not achieved
Check against Work instruction and Visual
Missing Process functional 6 Not follow sequence 3 4 72 N/A N/A N/A N/A N/A N/A N/A N/A
inspection
requirement

Warpage / Not achieved

Wrong processing
flatness of the functional 6 4 Check against Process Control Plan (PCP) 2 48 N/A N/A N/A N/A N/A N/A N/A N/A
checklist
parts requirement

Warpage / Not achieved

Wrong processing Work Instruction & Checking jig
flatness of the functional 6 4 2 48 N/A N/A N/A N/A N/A N/A N/A N/A
checklist (Poka Yoke)
parts requirement

Out-going inspection Appearance not Scrapped part In-process inspection

7 4 Check against PMP 3 84 N/A N/A N/A N/A N/A N/A N/A N/A
acceptable produced failed to detect

Wrong delivery Wrong entry of

Wrong Label 4 2 Check Label when paste 7 56 N/A N/A N/A N/A N/A N/A N/A N/A
part to Customer information

Sampling Method
Escape of
not thorough,
dimensional & Final Inspection follow the Outgoing
Customer rejection 7 process capability 2 3 42 N/A N/A N/A N/A N/A N/A N/A N/A
appearance inspection report sheet
not good,
defective parts
inconsistent quality

Sent Rejected Part Inspection failed to Check using process

Missing inspection 7 2 3 42 N/A N/A N/A N/A N/A N/A N/A N/A
to Customer detect drawing
 Existence of QC outgoing approval stamp
Unidentified parts Defective parts No QC outgoing
7 2 on every carton to be verified by store 3 42 N/A N/A N/A N/A N/A N/A N/A N/A
released to store sent to customer approval
prior to storage
Not following
Functionality may
Packaging Damage 6 Packaging 3 Check against Packing Instruction 4 72 N/A N/A N/A N/A N/A N/A N/A N/A
be affected
Instruction

Not following
Functionality may Conduct testing before implementation
Packaging Damage 3 Packaging 2 2 12 N/A N/A N/A N/A N/A N/A N/A N/A
be affected following procedure
Requirement
Operator did not
follow in process
Missing label Customer rejection 4 2 Supervisor and line leader verify 7 56 N/A N/A N/A N/A N/A N/A N/A N/A
inspection
instructions
Storage Unidentified parts
Wrong Part sent to No Approval from Store Keeper Verify the Label Before
release to 7 3 3 63 N/A N/A N/A N/A N/A N/A N/A N/A
Customer Inspector storage
store

Wrong Packing No Follow Packing

Part may damage 4 2 Check against Packing Instruction 4 32 N/A N/A N/A N/A N/A N/A N/A N/A
Method Instruction

Unproper Make signage for location and

Misplace part Delay shipment 6 3 4 72 N/A N/A N/A N/A N/A N/A N/A N/A
arrangement identification
Operator did not
Mixed parts or follow in-process
Customer rejection 3 2 Supervisor and line leader verify 7 42 N/A N/A N/A N/A N/A N/A N/A N/A
lots inspection
instruction
Wrong Qty Sent to Wrong information
Shortage 4 3 Verify the shipment list 2 24 N/A N/A N/A N/A N/A N/A N/A N/A
customer by planner

Rejected by
Wrong quantity customer due to Wrong information Preparation of D/O and verified with
2 2 7 28 N/A N/A N/A N/A N/A N/A N/A N/A
sent to customer wrong quantity given by planner planner
sent
No / wrong data Rejected by
Delivery Wrong information
package sent to customer upon 2 2 Verified by shipping clerk prior to delivery 7 28 N/A N/A N/A N/A N/A N/A N/A N/A
given by QA
customer receipt
Rejected by
Store Keeper not
Wrong sent part customer 2 2 Verify the shipment list 7 28 N/A N/A N/A N/A N/A N/A N/A N/A
alert
upon received
Doc Rev No. Revision Description Date
00 Supersede from Process Failure Mode And Effect Analysis (FM-QCD-45 to Process Failure Mode and Effect Analysis (FM-ENG-16) 01-Dec-16
01 Added Value ˃125 or customer specific requirement __________________(Action Needed) 25-Oct-21
02 Added PFMEA Number Column 18-Jan-22
03 Change value of RPN control from value ˃125 to value ˃100 28-Apr-22
04 Change PFMEA revision to Revision part number and added history revision column 28-Jun-22