Potential Failure Mode And Effects Analysis (Design FMEA)

FMEA Number:
Item: Process Responsibility: Page: of
Model Year(s)/Program(s) Key Date Prepared By:
Core Team: FMEA Date (orig):

Action Results

Classification

Occurrence

Detection

Occurrence
Severity
Process Responsibility &

Detection
Severity
Potential Effect(s) of Current Process Controls Current Process Controls Recommended

RPN
Step / Potential Failure Mode Potential Cause(s) of Failure Target Completion Actions Taken &

RPN
Failure (Prevention) (Detetion) Action
Function Date Effective Date
Process Flow Diagram
Part Number: DATE:
Part Description: ECL:
Prepared By: PREPARED BY:
FABRICATION

INSPECT
STORE
MOVE
PRODUCT AND

ITEM #

ITEM #
OPERATION PROCESS CONTROL
STEP DESCRIPTION CHARACTERISTICS METHODS

WGW-QUA-F-092 14-Jun-13
Potential Failure Mode And Effects Analysis (Process FMEA)
FMEA Number:

Item: Process Responsibility: Page: of

Model Year(s)/Program(s) Key Date Prepared By:
Core Team: FMEA Date (orig):

Action Results

Classification

Occurrence
Responsibility

Detection
Severity

Occurrence
Process

Detection
Potential Effect(s) of Current Process Controls Current Process Controls Recommended & Target

RPN

Severity
Step / Potential Failure Mode Potential Cause(s) of Failure Actions Taken &

RPN
Failure (Prevention) (Detetion) Action Completion
Function Effective Date
Date
Control Plan
Prototype Pre-Launch Production

Control Plan Number Key Contact/Phone Date (Orig.) Date (Rev.)

Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd.)

Part Name/Description Supplier/Plant Approval/Date Customer Quality Approval/Date (If Req'd.)

Supplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)

Part / Process Name / Machine, Reactiion Plan

Process Operation Device, Jig, CHARACTERISTICS METHODS

Classification
Number Description Tools for
Manufacturing, SAMPLE
Product / Process Evaluation /
etc… Specification / Measurement SIZE FREQ.
Number Product Process Tolerance Technique Control Method
Gage Repeatability And Reproducibility Data Sheet Variable Data Results
Part Number Gage Name Appraiser A
#REF!
Part Name Gage Number Appraiser B
#REF!
Characteristic Gage Type Appraiser C

Characteristic Classification Trials Parts Appraisers Date Performed

0 0 0

Measurement Unit Analysis % Tolerance (Tol)

Repeatability - Equipment Variation (EV)
EV = 𝑅 ̿ x K1 Trials K1 % EV = 100 (EV/Tol)
= 2 4.56 =
= 3 3.05 =
Reproducibility - Appraiser Variation (AV)
√( 𝑋 ̅
) {( DIFF x K2) - (EV /nr)}
2 2
AV = % AV = 100 (AV/Tol)
= =
= Appraisers 2 3 =
K2 3.65 2.70 n = number of parts
Repeatability & Reproducibility (R & R) r = number of trials
√(
R&R = {(EV )+ AV )}
2 2
Parts K3

= 2 3.65 % R&R = 100 (R&R/Tol)

= 3 2.70 =
Part Variation (PV) 4 2.30 =
PV = RP x K3 5 2.08
= 6 1.93
= 7 1.82 % PV = 100 (PV/Tol)
Tolerance 8 1.74 =
Tol = Upper - Lower 9 1.67 =
= USL - LSL 10 1.62
=

All calculations are based upon predicting 5.15 sigma (99.0% of the area under the normal distribution curve).
K1 is 5.15/d2, where d2 is dependent on the number of trials (m) and the number if parts times the number of operators (g) which is
assumed to be greater than 15.
AV - If a negative value is calculated under the square root sign, the appraiser variation (AV) defaults to zero (0).
K2 is 5.15/d2, where d2 is dependent on the number of operators (m) and (g) is 1, since there is only one range calculation.
K2 is 5.15/d2, where d2 is dependent on the number of parts (m) and (g) is 1, since there is only one range calculation.
d2 is obtained from Table D3, "Quality Control and Industrial Statistics", A.J. Duncan.
 Gage Repeatability And Reproducibility Report Short Form Attribute Results

Part Number Gage Name Appraiser A

Part Name Gage Number Appraiser B

Characterisitic/Specification Gage Type Date Performed

APPRAISER A APPRAISER B
PART # TRIAL #1 TRIAL #2 PART # TRIAL #1 TRIAL #2
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
10 10
11 11
12 12
13 13
14 14
15 15
16 16
17 17
18 18
19 19
20 20

All measurement decisions agree? Yes Accept Gage

No Reject Gage

Remarks
tribute Results
 Page 8 of 12 Pages

Dimensional Results
ORGANIZATION: Fulla Sheet Metal Stamping Inc. PART NUMBER: 11686446
SUPPLIER CODE: 40-112 PART NAME: Lock Spring Clip, PSC2
NAME OF INSPECTION FACILITY: DESIGN RECORD CHANGE LEVEL: X3
ENGINEERING CHANGE DOCUMENTS:

USL LSL
DIMENSION/SPECIFICATIO TEST QTY. ORGANIZATION MEASUREMENT RESULTS NOT
ITEM N DATE TESTED (DATA) OK OK
1 0.126 0.003 0.000 04/18/21 5 0.1271 0.1274 0.1282 0.1277 0.1275 X
2 0.30 04/18/21 5 0.33 0.31 0.31 0.31 0.32 X
3 0.27 04/18/21 5 0.25 0.25 0.26 0.25 0.26 X
4 0.610 0.008 0.008 04/18/21 5 0.6114 0.6122 0.6109 0.6202 0.6120 X
5 0.46 04/18/21 5 0.48 0.48 0.49 0.48 0.49 X

Blanket statements of conformance are unacceptable for any test results.

SIGNATURE TITLE DATE

 Page 12 of 9 Pages
Material Test Results
ORGANIZATION: PART NUMBER:
SUPPLIER/VENDOR CODE: PART NAME:
MATERIAL SUPPLIER: DESIGN RECORD CHANGE LEVEL:
*CUSTOMER SPRCIFIED SUPPLIER/VENDOR CODE: ENGINEERING CHANGE DOCUMENTS:
*If source approval is req'd, include the Supplier (Source) & Customer assigned code. NAME OF LABORATORY:
SPECIFICATION / TEST QTY. NOT
MATERIAL SPEC. NO. / REV / DATE LIMITS DATA TESTED SUPPLIER TEST RESULTS (DATA) OK OK

Blanket statements of conformance are unacceptable for any test results.

SIGNATURE TITLE DATE

 Page 10 of 12 Pages

Performance Test Results

SUPPLIER: PART NUMBER:
SUPPLIER/VENDOR CODE: PART NAME:
NAME OF LABORATORY: DESIGN RECORD CHANGE LEVEL:
*CUSTOMER SPECIFIED SUPPLIER/VENDOR C ENGINEERING CHANGE DOCUMENTS:
*If source approval is req'd, include the Supplier (Source) & Customer assigned code.

SPECIFICATION TEST QTY. NOT

TEST SPECIFICATIONS / REV / DATE / LIMITS DATE TESTED SUPPLIER TEST RESULTS (DATA) / TEST CONDITIONS OK OK

Blanket statements of conformance are unacceptable for any test results.

SIGNATURE TITLE DATE

Appearance Approval Report
PART DRAWING APPLICATION
NUMBER NUMBER (VEHICLES)
PART BUYER E/C LEVEL DATE
NAME CODE
ORGANIZATION MANUFACTURING SUPPLIER
NAME LOCATION CODE
REASON FOR PART SUBMISSION WARRANT SPECIAL SAMPLE RE-SUBMISSION OTHER
SUBMISSION PRE TEXTURE FIRST PRODUCTION SHIPMENT ENGINEERING CHANGE
APPEARANCE EVALUATION
AUTHORIZED CUSTOMER
ORGANIZATION SOURCING AND TEXTURE INFORMATION PRE-TEXTURE REPRESENTATIVE
EVALUATION SIGNATURE AND DATE
CORRECT
AND PROCEED
CORRECT AND
RESUBMIT
APPROVED TO
ETCH/TOOL/EDM
COLOR EVALUATION
TRISTIMULUS DATA METALLIC COLOR
COLOR MASTER MASTER MATERIAL MATERIAL HUE VALUE CHROMA GLOSS BRILLIANCE SHIPPING PART
SUFFIX DL* Da* Db* DE* CMC NUMBER DATE TYPE SOURCE RED YEL GRN BLU LIGHT DARK GRAY CLEAN HIGH LOW HIGH LOW SUFFIX DISPOSITION

COMMENTS:

ORGANIZATION PHONE NO. DATE AUTHORIZED CUSTOMER DATE

SIGNATURE REPRESENTATIVE SIGNATUR
Part Submission Warrant
Part Name Cust. Part Number

Shown on Drawing Number Org. Part Number

Engineering Change Level Dated

Additional Engineering Changes Dated

Ye
Safety and/or Government Regulation No Purchase Order No. Weight (kg)
s
Checking Aid No. Checking Aid Engineering Change Level Dated

ORGANIZATION MANUFACTURING INFORMATION CUSTOMER SUBMITTAL INFORMATION

Supplier Name & Supplier/Vendor Code Customer Name/Division

Street Address Purchasing Contact

Application
City Region Country Zip/Postal

MATERIALS REPORTING
Has Customer-required Substances of Concern information been reported? Yes No n/a

Submitted by IMDS or other Customer format: IMDS

Other Customer format
Are polymeric parts identified with appropriate ISO marking codes? Yes No n/a
REASON FOR SUBMISSION (Check at lease one)
Initial submission Change to Optional Construction or Material
Engineering Change(s) Sub-Supplier or Material Source Change
Tooling: Transfer, Replacement, Refurbishment, or additional Change in Part Processing
Correction of Discrepancy Parts produced at Additional Location
Tooling Inactive > than 1 year Other - please specify

REQUESTED SUBMISSION LEVEL (Check one)

Level 1 - Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to customer.
Level 2 - Warrant with product samples and limited supporting data submitted to customer.
Level 3 - Warrant with product samples and complete supporting data submitted to customer.
Level 4 - Warrant and other requirements as defined by customer.
Level 5 - Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location.

SUBMISSION RESULTS
The results for dimensional measurements material and functional tests appearance criteria statistical process package
These results meet all design record requirements: YES NO (If "NO" - Explanation Required)
Mold / Cavity / Production Process

DECLARATION

I affirm that the samples represented by this warrant are representative of our parts, which were made by a process that meets all
Production Part Approval Process Manual 4th Edition Requirements. I further affirm that these samples were produced at the production
rate of ______ / ______ hours. I also certify that documented evidence of such compliance is on file and available for review. I have noted
any deviations from this declaration below.
EXPLANATION/COMMENTS:

Is each Customer Tool properly tagged and numbered? YES NO

Organization Authorized Signature: Date

Print Name Phone No. Fax No.

Title E-mail

FOR CUSTOMER USE ONLY (IF APPLICABLE)

Approve
Part Warrant Disposition: Rejected Other
d
Customer Signature
Print Name Customer Tracking Number (optional)