POTENTIAL

System 1 - Automobile FAILURE MODE AND EFFECTS ANALYSIS FMEA Number 1234
Subsystem 2 - Body Closures Front Door L.H. Page 4 of 9
X Component 3 - Front Door L.H. Design Responsibility Body Engineering Prepared By A. Tate - X6412 - Body Engr
Model Year(s)/Program(s) 199X/Lion 4dr/Wagon Key Date 3/3/2003 FMEA Date (Orig.) 2/28/2003 (Rev) 3/3/2003
Core Team T. Fender - Car Product Dev., C. Childers - Manufacturing, J. Ford - Assy Ops (Dalton, Fraser, Henley Assembly Plants)

Action Results
Item
Potential

Occur

Detec
Class
Potential Effect(s) of Current Design Responsibility &

RPN
Sev
Potential Failure Mode Cause(s)/Mechanism(s) of Recommended Action(s)
Failure Controls Target Completion Date

RPN
Occ
Failure

Sev

Det
Function Actions Taken

3 - Front Door L.H.

- Ingress to and egress from Corroded interior lower door Deteriorated life of door 7 Upper edge of protective 6 Vehicle general 7 294 Add laboratory accelerated A. Tate Body Engrg Based on test results 7 2 2 28
vehicle. panels leading to: wax application specified for durability test veh. corrosion testing. - 2/25/2003 (Test No. 1481) upper
- Occupant protection from - Unsatisfactory appearance inner door panels is too low. T-118 edge spec raised 125
weather, noise, and side due to rust through paint T-109 mm.
impact. over time. T-301
- Support anchorage for - Impaired function of
door hardware including interior door hardware.
mirror, hinges, latch and
window regulator.
- Provide proper surface for Insufficient wax thickness 4 Vehicle general 7 196 Add laboratory accelerated A. Tate Body Engrg Test results (Test No. 7 2 2 28
appearance items - paint specified. durability testing - corrosion testing. - 3/28/2003 1481) show specified
and soft trim. as above. thickness is adequate.
- Detection

Conduct Design of A. Tate Body Engrg DOE shows 25%

Experiments (DOE) on - 3/28/2003 variation in specified
wax thickness. thickness is acceptable.

Inappropriate wax 2 Physical and 2 28 7 2 2 28

formulation specified. Chem Lab test -
Report No. 1265.
- Detection

Entrapped air prevents wax 5 Design aid 8 280 Add team evaluation using Body Engrg & Assy Ops Based on test, addition 7 1 3 21
from entering corner/edge investigation with production spray - 3/28/2003 vent holes will be
access. nonfunctioning equipment and specified provided in affected
spray head. wax. areas.
- Detection
Wax application plugs door 3 Laboratory test 1 21 7 3 1 21
drain holes. using "worst case"
wax application
and hole size.
- Detection

Insufficient room between 4 Drawing 4 112 Add team evaluation using Body Engrg & Assy Ops Evaluation showed 7 1 1 7
panels for spray head evaluation of design aid buck and spray - 3/28/2003 adequate access.
access. spray head head.
access.
- Detection

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Document Created 3/26/2003 Generated By ReliaSoft’s Xfmea Software http://www.ReliaSoft.com
 RECOMMENDED ACTIONS
(Summary Report)
Date: 3/26/2003
Page 5 of 9

Potential
Target
# Recommended Action(s) Responsibility Actions Taken Item Cause(s)/Mechanism(s) of Priority
Completion Date
Failure
1 Add laboratory accelerated corrosion testing. 2/25/2003 A. Tate Body Engrg Based on test results (Test No. 1481) Front Door L.H. Upper edge of protective wax
upper edge spec raised 125 mm. application specified for inner
door panels is too low.

2 Add laboratory accelerated corrosion testing. 3/28/2003 A. Tate Body Engrg Test results (Test No. 1481) show specified Front Door L.H. Insufficient wax thickness
thickness is adequate. specified.
3 Conduct Design of Experiments (DOE) on wax 3/28/2003 A. Tate Body Engrg DOE shows 25% variation in specified Front Door L.H. Insufficient wax thickness
thickness. thickness is acceptable. specified.
4 Add team evaluation using production spray equipment 3/28/2003 Body Engrg & Assy Ops Based on test, addition vent holes will be Front Door L.H. Entrapped air prevents wax from
and specified wax. provided in affected areas. entering corner/edge access.

5 Add team evaluation using design aid buck and spray 3/28/2003 Body Engrg & Assy Ops Evaluation showed adequate access. Front Door L.H. Insufficient room between panels
head. for spray head access.

Non-proprietary and non-confidential information.

Document Created 3/26/2003 Generated By ReliaSoft’s Xfmea Software http://www.ReliaSoft.com
 CURRENT CONTROLS
Date: 3/26/2003
Page 6 of 9

Potential
# Current Design Controls Control Type Item Function Potential Failure Mode Potential Effect(s) of Failure Cause(s)/Mechanism(s) of
Failure
1 Vehicle general durability test veh. Detection Front Door L.H. - Ingress to and egress from vehicle Corroded interior lower door Deteriorated life of door leading to: Upper edge of protective wax
T-118 - Occupant protection from weather, noise, and panels - Unsatisfactory appearance due to application specified for inner
T-109 side impact rust through paint over time door panels is too low.
T-301 - Support anchorage for door hardware including - Impaired function of interior door
mirror, hinges, latch and window regulator hardware
- Provide proper surface for appearance items -
paint and soft trim

2 Vehicle general durability testing - as Detection Front Door L.H. - Ingress to and egress from vehicle Corroded interior lower door Deteriorated life of door leading to: Insufficient wax thickness
above. - Occupant protection from weather, noise, and panels - Unsatisfactory appearance due to specified.
side impact rust through paint over time
- Support anchorage for door hardware including - Impaired function of interior door
mirror, hinges, latch and window regulator hardware
- Provide proper surface for appearance items -
paint and soft trim

3 Physical and Chem Lab test - Report No. Detection Front Door L.H. - Ingress to and egress from vehicle Corroded interior lower door Deteriorated life of door leading to: Inappropriate wax formulation
1265. - Occupant protection from weather, noise, and panels - Unsatisfactory appearance due to specified.
side impact rust through paint over time
- Support anchorage for door hardware including - Impaired function of interior door
mirror, hinges, latch and window regulator hardware
- Provide proper surface for appearance items -
paint and soft trim

4 Design aid investigation with Detection Front Door L.H. - Ingress to and egress from vehicle Corroded interior lower door Deteriorated life of door leading to: Entrapped air prevents wax from
nonfunctioning spray head. - Occupant protection from weather, noise, and panels - Unsatisfactory appearance due to entering corner/edge access.
side impact rust through paint over time
- Support anchorage for door hardware including - Impaired function of interior door
mirror, hinges, latch and window regulator hardware
- Provide proper surface for appearance items -
paint and soft trim

5 Laboratory test using "worst case" wax Detection Front Door L.H. - Ingress to and egress from vehicle Corroded interior lower door Deteriorated life of door leading to: Wax application plugs door drain
application and hole size. - Occupant protection from weather, noise, and panels - Unsatisfactory appearance due to holes.
side impact rust through paint over time
- Support anchorage for door hardware including - Impaired function of interior door
mirror, hinges, latch and window regulator hardware
- Provide proper surface for appearance items -
paint and soft trim
6 Drawing evaluation of spray head access. Detection Front Door L.H. - Ingress to and egress from vehicle Corroded interior lower door Deteriorated life of door leading to: Insufficient room between panels
- Occupant protection from weather, noise, and panels - Unsatisfactory appearance due to for spray head access.
side impact rust through paint over time
- Support anchorage for door hardware including - Impaired function of interior door
mirror, hinges, latch and window regulator hardware
- Provide proper surface for appearance items -
paint and soft trim

Non-proprietary and non-confidential information.

Document Created 3/26/2003 Generated By ReliaSoft’s Xfmea Software http://www.ReliaSoft.com