Automotive FMEA

Process Failure Mode And Effects Analysis Low - High

Process: Outside Suppliers Affected: Engineer: 1 - 10

Primary Process Responsibility: Model Year/Vehicle(s): Part Number:
Other Div. Or People Involved: Scheduled Production Released: PFMEA Date: Rev.

Approvals: Quality Assurance Manager Quality Assurance Engineer

Operations Manager Senior Advisor

Detection
Occured
Part Name Recommended

Severity
Operation Potential Failure Potential Effects Of Actions And Actions Responsible

RPN
Number Process Function Mode Failure Potential Cause Of Failure Current Controls Status Taken Activity
SIR Take TPPE Wrong Material Fragmented Container Insufficient Supplier Control Material Certification 1 9 2 18

Container Material Held In Unpredictable Deployment Improper Handling Required With Each
1 Storage Area Misidentified Material Shipment
Release Verification
Out Of Spec Fragmented Container Supplier Process Control Periodic Audit Of 3 10 3 90
Material Unpredictable Deployment Supplier Material
Contaminated Fragmented Container Open Boxes Visual Inspection 1 9 7 63
Material Unpredictable Deployment
Material Fragmented Container Engineering Change Release Verification 1 10 7 70
Composition Unpredictable Deployment Supplier Change Green "OK" Tag
Change Customer Notification
2 Move To Unreleased Fragmentation Untrained LTO Check For Green "OK" 5 10 1 50

Approved Untrained Personnel Tag At Press

Storage Trace Card
Check List
Training

Leading to MSA. Critical features are determined by the FMEA

(RPN indicators) and put into the Control Plan.
Control Plan / Flow Diagram
47

 Inspection Points
 Inspection Frequency
 Instrument
 Measurement Scale
 Sample Preparation
 Inspection/Test Method
 Inspector (who?)
 Method of Analysis
 GM Process Flow Chart
Process Flow Diagram Approved By:

Part Number: Date: 4/5/93 QA Manager

Part Description: Rev. : C Operations Manager
Prepared By: Senior Advisor
QA Engineer
Fabrication

Inspect
Move

Store

Step Operation Description Item # Key Product Characteristic Item # Key Control Characteristic

1 Move "OK" Vinyl Material 1.0 Material Specs 1.0 Material Certification Tag
From Storage Area and
Load Into Press.

2 Auto Injection Mold Cover 2.0 Tearstrip In Cover 2.1 Tool Setup
In Tool # 2.2 Machine Setup

3.0 Hole Diameter In Cover 2.1 Tool Setup

2.2 Machine Setup

4.0 Flange Thickness In Cover 2.1 Tool Setup

2.2 Machine Setup

5.0 Pressure Control Protrusions 2.1 Tool Setup

Height 2.2 Machine Setup

3 Visually Inspect Cover 6.0 Pressure Control Protrusions 2.1 Tool Setup
Filled Out 2.2 Machine Setup
Standard Control Plan Example
49
Control Plan Number Key Contact / Phone Date (Orig.) Date (Rev.)

Part No./ Latest Change No. Core Team Customer Engineering Approval/Date

Part Name/Description Supplier/Plant Apoproval/Date Customer Quality Approval/Date

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

Characteristics Methods
Machine, Product/
Part/ Process Name/ Device, Special Process Evaluation
Process Operation Jig, Tools Char. Spec/ Measurement Frequ- Control Reaction
Number Description for Mfg. No. Product Process Class Tolerance Technique Size ency Method Plan

This form is on course disk

Ford’s Dimensional Control Plan (DCP)
50