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Completely Reformatted Failure Mode and Effects Analysis Form Completely Reformatted

Combined Design & Process FMEA Barb-Ty Cable Ties

FMEA Type: Combined Design and Process FMEA or ECN Number: W3-1383
Project / Product / Purpose: BT Product Family Original Date: 8/27/1993 Approved By: MED CE: TGS OPERATIONS MGR: SP
Team Leader: DAPC Revised Date: 1/3/2012 Approved By: QA: KJM
FMEA Team: DAPC, JADE, MPH, CR-SMA File Location: PanDocs
FMEA 200 TARGET RPN Action Results

Classification

Occurrence

Occurrence
Detection

Detection
Responsibility and

Severity

Severity
RPN
Potential Effect(s) of Current Controls Current Controls Recommended

RPN
Function / Item / Process Potential Failure Mode Potential Cause(s) of Failure Target Completion Action Taken
Failure Prevention Detection Action
Date

Receive Raw Material Low or no Tensile Not Usable 7 P Wrong Material D - Supplier 2 Incoming Inspection 3 42
Qualifications Procedures
P - Material ID, Material
Certificates
Material out of Specification D - Supplier 1 Incoming Inspection 3 21
Qualifications Procedures
P - Material ID, Material
Certificates
Holes in Bag D - Supplier 3 Incoming Inspection, MII, 3 63
Qualifications, Material In-Process Audit, FG
Certificates Audit
Body Breaks Not Usable 7 Wrong Material D - Supplier 2 Incoming Inspection 3 42
Qualifications Procedures
P - Material ID, Material
Certificates
Material out of Specification D - Supplier 1 Incoming Inspection 3 21
Qualifications Procedures
P - Material ID, Material
Certificates
Short Tie Not Usable on Larger 7 Wrong Material D - Supplier 2 Incoming Inspection 3 42
Bundles Qualifications Procedures
P - Material ID, Material
Certificates
Material out of Specification D - Supplier 1 Incoming Inspection 3 21
Qualifications Procedures
P - Material ID, Material
Certificates
Flexibility Difficult to Apply 5 Wrong Material D - Supplier 2 Incoming Inspection 3 30
Qualifications Procedures
P - Material ID, Material
Certificates
Material out of Specification D - Supplier 1 Incoming Inspection 3 15
Qualifications Procedures
P - Material ID, Material
Certificates
Store Raw Material Expired Shelf Life Mold Settings May Need 1 Material Not Consumed Before P - Inventory Turns 1 FIFO, Oracle 1 1
Adjusting Shelf Life Expiration
Blend Material Low or no Tensile Not Usable 7 P Wrong Material Mix D - Formulation Sheets 2 Alarm for Adverse 3 42
P - Work Instructions, Machine Conditions, Cell
Weight Measurements Audits
Body Breaks Not Usable 7 Wrong Material Mix D - Formulation Sheets 2 Alarm for Adverse 3 42
P - Work Instructions, Machine Conditions, Cell
Weight Measurements Audits
Short Tie Not Usable on Larger 7 Wrong Material Mix D - Formulation Sheets 2 Alarm for Adverse 3 42
Bundles P - Work Instructions, Machine Conditions, Cell
Weight Measurements Audits
Flexibility Difficult to Apply 5 Wrong Material Mix D - Formulation Sheets 2 Alarm for Adverse 3 30
P - Work Instructions, Machine Conditions, Cell
Weight Measurements Audits
Wrong Color Customer Dissatisfied 3 Wrong Material Mix D - Formulation Sheets 2 Alarms for Adverse 3 18
P - Work Instructions, Machine Conditions, First
Weight Measurements Piece Inspection, MII, In-
Process Audit, FG Audit

Transfer Material to Molding Low or no Tensile Not Usable 7 P Wrong Material Used for Recipe P - Setup Procedures, Bill 1 Alarms for Adverse 3 21
of Materials, Material ID Machine Conditions, First
Piece Inspection, MII, In-
Process Audit, FG Audit

Body Breaks Not Usable 7 Wrong Material Used for Recipe P - Setup Procedures, Bill 1 Alarms for Adverse 3 21
of Materials, Material ID Machine Conditions, First
Piece Inspection, MII, In-
Process Audit, FG Audit

Appr: KJM Date 03 Jan 12 1 of 5

 Completely Reformatted Failure Mode and Effects Analysis Form Completely Reformatted

Combined Design & Process FMEA Barb-Ty Cable Ties

FMEA Type: Combined Design and Process FMEA or ECN Number: W3-1383
Project / Product / Purpose: BT Product Family Original Date: 8/27/1993 Approved By: MED CE: TGS OPERATIONS MGR: SP
Team Leader: DAPC Revised Date: 1/3/2012 Approved By: QA: KJM
FMEA Team: DAPC, JADE, MPH, CR-SMA File Location: PanDocs
FMEA 200 TARGET RPN Action Results

Classification

Occurrence

Occurrence
Detection

Detection
Responsibility and

Severity

Severity
RPN
Potential Effect(s) of Current Controls Current Controls Recommended

RPN
Function / Item / Process Potential Failure Mode Potential Cause(s) of Failure Target Completion Action Taken
Failure Prevention Detection Action
Date

Short Tie Not Usable on Larger 7 Wrong Material Used for Recipe P - Setup Procedures, Bill 1 Alarms for Adverse 3 21
Bundles of Materials, Material ID Machine Conditions, First
Piece Inspection, MII, In-
Process Audit, FG Audit

Flexibility Difficult to Apply 5 Wrong Material Used for Recipe P - Setup Procedures, Bill 1 Alarms for Adverse 3 15
of Materials, Material ID Machine Conditions, First
Piece Inspection, MII, In-
Process Audit, FG Audit

Wrong Color Customer Dissatisfied 3 Wrong Material Used for Recipe P - Setup Procedures, Bill 1 First Piece Inspection, 3 9
of Materials, Material ID MII, In-Process Audit, FG
Audit
Molding Low Tensile Not Usable for Customer 5 P Barb Gap too Big D - Head Holding Pins, 6 First Piece Inspection, 2 60
Requirements Cover Plates, Training Tensile Test - First Piece, In-
P - Setup Procedures Process Inspection, In-Process
Audit, FG Audit
Damaged Barb Edges P - Setup Procedures, 3 First Piece Inspection, 3 45
PM Program MII, In-Process Audit

Barb Material Hardness D - Supplier 1 Incoming Inspection 2 10

Qualifications Procedures
P - Material ID, Material
Certificates
Undersized Barb Width / D - Supplier 1 Incoming Inspection 2 10
Thickness Qualifications Procedures
P - Material ID, Material
Certificates
Barb Length D - Barb Wire Encoders 1 First Piece Inspection, 2 10
S t P
P - Setup d
Procedures, T il T
Tensile Testt - First Piece, In-
PM Program Process Inspection, In-Process
Audit, FG Audit
Voids / Sinks in Head P - Setup Procedures 3 First Piece Inspection, 5 75
MII, In-Process Audit, FG
Audit
Body Thickness P - Setup Procedures, 1 Mold Approval Process, 3 15
PM Program, CPM 3.0 First Piece Inspection

Incorrect Barb Angle D - Revised "S" Relief 1 First Piece Inspection, 7 35

Cores Tensile Test - First Piece, In-
P - Setup Procedures Process Inspection, In-Process
Audit, FG Audit
Barb Curved / Bowed P - Setup Procedures 1 First Piece Inspection, 7 35
Tensile Test - First Piece, In-
Process Inspection, In-Process
Audit, FG Audit
Heads Sticking P - Setup Procedures, 2 First Piece Inspection, MII 5 50
PM Program, CPM 3.0,
Control Mold Temp
No Tensile Not Usable 8 P Missing Barb P - Setup Procedures 3 Missing Barb Sensor, 8 192 Install automatic CR-WQP
First Piece Inspection, segragation tooling Jan-12
MII, In-Process that will be controlled
Inspection, In-Process by the missing barb
Audit, FG Audit sensor.
Incorrect Barb Angle D - Revised "S" Relief 1 First Piece Inspection, 4 32
Cores Tensile Test - First Piece,
P - Setup Procedures, In-Process Inspection, In-
Barb Adjustment Process Audit, FG Audit
Flowchart
Short Shots P - Setup Procedures, 1 CPM 3.0, First Piece 4 32
Control Mold Temp, Inspection, MII, In-
Machine In-Line Sensors Process Inspection, In-
Process Audit, FG Audit
Shattered Head P - Setup Procedures 2 First Piece Inspection, 4 64
MII, In-Process Audit, FG
Audit

Appr: KJM Date 03 Jan 12 2 of 5

 Completely Reformatted Failure Mode and Effects Analysis Form Completely Reformatted

Combined Design & Process FMEA Barb-Ty Cable Ties

FMEA Type: Combined Design and Process FMEA or ECN Number: W3-1383
Project / Product / Purpose: BT Product Family Original Date: 8/27/1993 Approved By: MED CE: TGS OPERATIONS MGR: SP
Team Leader: DAPC Revised Date: 1/3/2012 Approved By: QA: KJM
FMEA Team: DAPC, JADE, MPH, CR-SMA File Location: PanDocs
FMEA 200 TARGET RPN Action Results

Classification

Occurrence

Occurrence
Detection

Detection
Responsibility and

Severity

Severity
RPN
Potential Effect(s) of Current Controls Current Controls Recommended

RPN
Function / Item / Process Potential Failure Mode Potential Cause(s) of Failure Target Completion Action Taken
Failure Prevention Detection Action
Date

Barb Gap too Big / Not Engaging D - Head Holding Pins, 1 Missing Barb Sensor, 2 16
Body Cover Plates, Training First Piece Inspection,
P - Setup Procedures, Tensile Test - First Piece, In-
Machine In-Line Sensors Process Inspection, In-Process
Audit, FG Audit
Barb Length D - Barb Wire Encoders 1 First Piece Inspection, 2 16
P - Setup Procedures, Tensile Test - First Piece, In-
PM Program Process Inspection, In-Process
Audit, FG Audit
Body Thickness P - Setup Procedures, 1 Mold Approval Process, 3 24
PM Program, CPM 3.0 First Piece Inspection

Body Breaks Not Usable 8 Moisture, UMO, RV of Raw D - Supplier 2 Incoming Inspection 1 16
Material Qualifications Procedures, Alarm for
P - Material ID, Material Adverse Machine
Certificates, CPM 3.0 Conditions, Cell Audits,
FG Audits
Out of Tolerance Process D - Machine Recipes 1 Alarm for Adverse 1 8
Conditions P - Process Controls, Machine Conditions
CPM 3.0, PM Program,
Calibration Program,
Machine In-Line Sensors

Flow Lines P - Setup Procedures, 1 First Piece Inspection, 1 8

PM Program, CPM 3.0 MII, In-Process Audit, FG
Audit
Tooling not to Specification P - Setup Procedures 1 Mold Approval Process, 1 8
First Piece Inspection

Contamination P - Setup Procedures, 1 First Piece Inspection, 6 48

PM Program, Barrel MII, In-Process Audit, FG
Purging Procedures, Audit
Enclosed Hoppers, MDS

Zipback / Releasing Loose Bundle 4 Damaged Barb Edges P - Setup Procedures, 3 First Piece Inspection, 3 36
(Slippage) PM Program MII, In-Process Audit

Incorrect Barb Angle D - Revised "S" Relief 1 First Piece Inspection, 7 28

Cores Tensile Test - First Piece, In-
P - Setup Procedures Process Inspection, In-Process
Audit, FG Audit
Barb Gap Slightly too Big D - Head Holding Pins, 3 First Piece Inspection, 3 36
Cover Plates, Training Tensile Test - First Piece, In-
P - Setup Procedures Process Inspection, In-Process
Audit, FG Audit
Barb Length D - Barb Wire Encoders 1 First Piece Inspection, 2 8
P - Setup Procedures, Tensile Test - First Piece, In-
PM Program Process Inspection, In-Process
Audit, FG Audit
Tooling not to Specification P - Setup Procedures 1 Mold Approval Process, 1 4
First Piece Inspection

Body Thickness P - Setup Procedures, 1 First Piece Inspection, 3 12

PM Program, CPM 3.0, MII, In-Process Audit, FG
Machine In-Line Sensors Audit

Recipe not at standard Pan Cim 4 In-Process Audit 4 64

Appearance Customer Dissatisfied 3 Contamination P - Setup Procedures, 1 First Piece Inspection, 6 18

PM Program, Barrel MII, In-Process Audit, FG
Purging Procedures, Audit
Enclosed Hoppers, MDS

Appr: KJM Date 03 Jan 12 3 of 5

 Completely Reformatted Failure Mode and Effects Analysis Form Completely Reformatted

Combined Design & Process FMEA Barb-Ty Cable Ties

FMEA Type: Combined Design and Process FMEA or ECN Number: W3-1383
Project / Product / Purpose: BT Product Family Original Date: 8/27/1993 Approved By: MED CE: TGS OPERATIONS MGR: SP
Team Leader: DAPC Revised Date: 1/3/2012 Approved By: QA: KJM
FMEA Team: DAPC, JADE, MPH, CR-SMA File Location: PanDocs
FMEA 200 TARGET RPN Action Results

Classification

Occurrence

Occurrence
Detection

Detection
Responsibility and

Severity

Severity
RPN
Potential Effect(s) of Current Controls Current Controls Recommended

RPN
Function / Item / Process Potential Failure Mode Potential Cause(s) of Failure Target Completion Action Taken
Failure Prevention Detection Action
Date

Discoloration P - Setup Procedures, 2 First Piece Inspection, 3 18

Color Change MII, In-Process Audit, FG
Procedures, Barrel Audit
Purging Procedures
Bubbles / Voids P - Setup Procedures, 3 First Piece Inspection, 4 36
Machine In-Line Sensors MII, In-Process Audit, FG
Audit
Grease, Dirt, Rust P - PM Program, 5S 2 First Piece Inspection, 4 24
Program and Procedures MII, In-Process Audit, FG
Audit
Burns P - Setup Procedures, 2 First Piece Inspection, 3 18
Machine In-Line Sensors, MII, In-Process Audit, FG
PM Program Audit
Secondary Equipment Damage D - Trackless Trimmer / 1 First Piece Inspection, 6 18
Straight Track MII, In-Process Audit, FG
Audit
Flash P - Setup Procedures, 3 First Piece Inspection, 5 45
Machine In-Line Sensors, MII, In-Process Audit, FG
PM Program, CPM 3.0 Audit

Short Shots P - Setup Procedures, 1 First Piece Inspection, 1 3

PM Program, CPM 3.0 MII, In-Process Audit, FG
Audit
Short Tie Not Usable on Larger 7 Damaged Cavity P - PM Program 2 First Piece Inspection, 4 56
Bundles MII, In-Process Audit, FG
Audit
Short Shots P - Setup Procedures, 1 First Piece Inspection, 1 7
C
PM Program, CPM 30
3.0 MII In-Process
MII, I P A dit FG
Audit,
Audit
Sharp Edge Cut Hands and Bundle 7 Tooling not to Specification P - Setup Procedures 3 First Piece Inspection, 3 63
MII, In-Process Audit, FG
Audit
Parting Line Flash P - Setup Procedures, 2 First Piece Inspection, 1 14
PM Program, CPM 3.0 MII, In-Process Audit, FG
Audit
Poor Trim D - Trackless Trimmer 1 First Piece Inspection, 3 21
MII, In-Process Audit, FG
Audit
Blade placed backwards P - Pokayoke System 1 PM Program 3 21
Installation: Modify the
blade holder cavity
Flexibility Difficult to Apply 5 Body Thickness P - Setup Procedures, 1 First Piece Inspection, 5 25
PM Program, CPM 3.0, MII, In-Process Audit, FG
Machine In-Line Sensors Audit

High Thread Force Difficult to Apply 5 Barb Gap too Small D - Head Holding Pins, 1 First Piece Inspection, 3 15
Cover Plates, Training Tensile Test - First Piece, In-
P - Setup Procedures Process Inspection, In-Process
Audit, FG Audit
Tooling not to Specification P - Setup Procedures 3 First Piece Inspection, 4 60
MII, In-Process Audit, FG
Audit
Body Thickness P - Setup Procedures, 2 First Piece Inspection, 2 20
PM Program, CPM 3.0, MII, In-Process Audit, FG
Machine In-Line Sensors Audit

Incorrect Barb Angle D - Revised "S" Relief 2 First Piece Inspection, 7 70

Cores Tensile Test - First Piece, In-
P - Setup Procedures Process Inspection, In-Process
Audit, FG Audit
Packaging Incorrect Piece Count Stock Quantities Incorrect or 3 Sensor not Working Properly P - Setup Procedures 3 MII, In-Process Audit 8 72
Wrong Quantity Delivered

Appr: KJM Date 03 Jan 12 4 of 5

 Completely Reformatted Failure Mode and Effects Analysis Form Completely Reformatted

Combined Design & Process FMEA Barb-Ty Cable Ties

FMEA Type: Combined Design and Process FMEA or ECN Number: W3-1383
Project / Product / Purpose: BT Product Family Original Date: 8/27/1993 Approved By: MED CE: TGS OPERATIONS MGR: SP
Team Leader: DAPC Revised Date: 1/3/2012 Approved By: QA: KJM
FMEA Team: DAPC, JADE, MPH, CR-SMA File Location: PanDocs
FMEA 200 TARGET RPN Action Results

Classification

Occurrence

Occurrence
Detection

Detection
Responsibility and

Severity

Severity
RPN
Potential Effect(s) of Current Controls Current Controls Recommended

RPN
Function / Item / Process Potential Failure Mode Potential Cause(s) of Failure Target Completion Action Taken
Failure Prevention Detection Action
Date

Parts Falling Off P - Setup Procedures 3 MII, In-Process Audit 8 72

Loader / Trimmer Reset P - Setup Procedures 3 MII, In-Process Audit 8 72

4 Incorrect Number of Bags in a P - Counting Scale 4 MII, In-Process Audit 3 48

Box Setup, Counting Tables

Wrong Label Incorrect Tie, Not Usable 8 Incorrect Labels P - Setup Procedures, 5S 2 First Bag Audit, MII, In- 3 48
Program Process Audit, FG Audit

Incorrect Work Order P - Setup Procedures, 5S 2 First Bag Audit, MII, In- 3 48
Program Process Audit, FG Audit

Low Tensile Not Usable for Customer 5 P Poor Bag Seals D - Sealing Controls 2 MII, In-Process Audit, FG 2 20
Requirements (Header Bagger Project Audit
#9611669)
P - Setup Procedures
Incorrect Water Conditioning P - Setup Procedures 2 First Piece Inspection, 3 30
MII, In-Process Audit, FG
Audit
Body Breaks Not Usable 8 Incorrect Water Conditioning P - Setup Procedures 2 First Piece Inspection, 3 48
MII, In-Process Audit, FG
Audit
Flexibility Difficult to Apply 5 Incorrect Water Conditioning P - Setup Procedures 2 First Piece Inspection, 3 30
MII In-Process
MII, I P A dit FG
Audit,
Audit
Store Product in Warehouse Low Tensile May Not Be Usable for 5 Product Age D - Shelf Life Expiration 1 Visual when Picking 3 15
Customer Requirements P - FIFO, Oracle Orders
Discoloration Customer Dissatisfied 3 Product Age D - Shelf Life Expiration 1 Visual when Picking 3 9
P - FIFO, Oracle Orders

P in Classification Column denotes a priority failure mode

D or P in Current Controls Prevention Column denote a design control or a process control

Appr: KJM Date 03 Jan 12 5 of 5