POTENTIAL FAIL URE MODE AND EFFECTS ANAL YSIS (DESIGN FMEA) X System Subsystem Component Model Years

(s)/Vehicle(s) Core Team Chris Fox, Kerry Hinson 2008 XYZ Design Responsibility Dave Designer Key Date 6/27/2005 Page Prepared By FMEA Date (Orig.) Chris Fox 6/21/12 FMEA Number 05-XYZ

Action Results I t e m C L A S S

Part/ Part Number

Part Function

Failure Mode

Failure Effects

S E V

Causes/ Mechanisms of Failure

O C C

Current Design Controls

D E T

R P N

Recommended Actions

Responsibility & Target Completion Date

Actions Taken

S e v

O c c

D e t

R P N

Tool used for writing or drawing with a colored fluid, such as ink

Casing (Outer Tube)

Provides grip for writer

Casing designed too small

Won't fit in large hands comfortably, and could contribute to CTS.

6

Bad mating part (user's hand size) information

2

Print review system that includes evaluation of all mating parts, and possible clearance/interference issues by design team prior to release of print to toolmaker. Print review system that includes evaluation of all mating parts, and possible clearance/interference issues by design team prior to release of print to toolmaker.

4

48

Casing designed too large

Won't fit in small hands comfortably.

6

Bad mating part (user's hand size) information

2

4

48

Provides protection for mechanism and contents.

Ink reservoir will not actuate without binding.

Unable to move cartridge into point of operation without difficulty. Unable to move cartridge into point of operation

6

Internal cavity designed 2 too small

Tolerance stackup

4

48

Ink reservoir will not actuate, button mechanism pops off.

6

Internal cavity designed 2 too large

Tolerance stackup

4

48

Ink reservoir will not actuate, stylus larger than clearance hole.

Unable to move cartridge into point of operation

6

Hole designed too small. 2

Print review system that includes evaluation of all mating parts, and possible clearance/interference issues by design team prior to release of print to toolmaker.

4

48

Ink Reservoir

Stores ink until point of use.

Plastic material crossreacts with ink

Ink exhibits signs of contamination

6

Improper material selection.

2

Material Selection to reduce potential, and process controls

4

48

Leaks

Material failure - Cracks 6 or seepage.

Improper material selection.

2

Spray bar test, environmental testing.

4

48

Bent / Warped

Unable to move cartridge into point of operation

6

Improper material selection.

2

FEA to determine material suitability

4

48

Ink reservoir will not actuate without binding.

Unable to move cartridge into point of operation

6

Ink reservoir designed too large

2

Tolerance stackup

4

48

Cartridge profile incorrect

Unable to move cartridge into point of operation

6

Bad mating part information

2

Tolerance stackup

4

48

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POTENTIAL FAIL URE MODE AND EFFECTS ANAL YSIS (DESIGN FMEA) X System Subsystem Component Model Years(s)/Vehicle(s) Core Team Chris Fox, Kerry Hinson 2008 XYZ Design Responsibility Dave Designer Key Date 6/27/2005 Page Prepared By FMEA Date (Orig.) Chris Fox 6/21/12 FMEA Number 05-XYZ

Action Results I t e m C L A S S

Part/ Part Number

Part Function

Failure Mode

Failure Effects

S E V

Causes/ Mechanisms of Failure

O C C

Current Design Controls

D E T

R P N

Recommended Actions

Responsibility & Target Completion Date

Actions Taken

S e v

O c c

D e t

R P N

Ink Stylus

Act as a cap to keep the ink from drying

Accidentally dry in the pen

Ink gums the whole thing 6 up and requires meticulous cleaning

Designed overclearance 2

Acts as a buffer between the material and the quick-drying ink inside the pen

4

48

Lets ink flow out of the pen at a Flow unevenly controlled rate

Flow unevenly

6

Designed overclearance 2

Small rotating ball made of brass, steel or tungsten carbide to disperse ink

4

48

Clogged / Bound ballpoint

Flow unevenly

6

Clogged / Bound ballpoint

2

Reliability testing

4

48

Ballpoint Oversized

Flow unevenly

6

Ballpoint Oversized

2

Pre-production validation

4

48

Ballpoint Undersized

Flow unevenly

6

Ballpoint Undersized

2

Pre-production validation

4

48

Contamination / Corrosion

Flow unevenly

6

Contamination / Corrosion

2

Reliability testing

4

48

Bent / Warped

Flow unevenly

6

Bent / Warped

2

Material Selection to reduce potential, and process controls

4

48

Ink

Viscosity too thin

6

Wrong ingredient(s) for application

2

Materials Testing

4

48

Viscosity too thick

6

Wrong ingredient(s) for application

2

Materials Testing

4

48

Ingredient: Vehicle

Acts as fluid to transport pigmentsand coloring

Wrong formulation for writing substrate

Slow to dry

6

Wrong ingredient(s) for application

2

Pre-production validation, reliability testing

4

48

Ingredient: Coloring

Makes writing darker and clearer.

Color Missing

6

Wrong ingredient(s) for application

2

Pre-production validation, reliability testing

4

48

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POTENTIAL FAIL URE MODE AND EFFECTS ANAL YSIS (DESIGN FMEA) X System Subsystem Component Model Years(s)/Vehicle(s) Core Team Chris Fox, Kerry Hinson 2008 XYZ Design Responsibility Dave Designer Key Date 6/27/2005 Page Prepared By FMEA Date (Orig.) Chris Fox 6/21/12 FMEA Number 05-XYZ

Action Results I t e m C L A S S

Part/ Part Number

Part Function

Failure Mode Color Wrong

Failure Effects

S E V 6

O Causes/ Mechanisms C of Failure Current Design Controls C Wrong ingredient(s) for 2 Pre-production validation, reliability testing application

D R E P T N 4 48

Recommended Actions

Responsibility & Target Completion Date

Actions Taken

S e v

O c c

D e t

R P N

Ingredient: Additive

Stabilize and provide additional desirable characteristics.

6

Wrong ingredient(s) for application

2

Pre-production validation, reliability testing

4

48

Button Mechanism

Protects user and contents when not in use

Button stays in down position.

Ink leaks when not in use.

6

Spring failure / defective 2

Pre-production validation, reliability testing

4

48

6

Cam failure / defective

2

Pre-production validation, reliability testing

4

48

6

Contamination / Corrosion

2

Reliability testing

4

48

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