Boundary Diagram

PRODUCT NO:- CNT000005046 CUSTOMER PART NO:- DFMEA NO:- DFMEA/ETX/CNT000005046/00

PRODUCT NAME:- Unit Engine Shut Off Controller With CUSTOMER PART NAME:- Unit Engine Shut Off Controller
DATE:-
Seat Occupancy Timer Seat Occupancy

Environmental Mounting Force,Mating

Dust, Humidity, heat, Mounting on vehicle
Force
vibration

Electrical Noise
EMC
Electrical Noise
Battery (+ve)
EMC
Electrical Noise
EMC
Battery (+ve)
Output Signal
Electrical Noise
EMC
Ignition Supply
Electrical Noise
EMC
Seat Occcupancy

CORE TEAM Mechanical Contact

DEPARTMENT MEMBERS
Electrical Signal
R&D
QA Energy
PE
PROD
VENDOR DEV YH AN AN
PREPARED CHECKED APPROVED
PRODUCT NO:-CNT000005046 CUSTOMER PART NO:- DFMEA NO:- DFMEA/ETX/CNT000005046/00
PRODUCT NAME:- Unit Engine Shut Off Controller With Seat Occupancy CUSTOMER PART NAME:- Unit Engine Shut Off Controller DATE:-06.04.2016
P-DIAGRAM
Timer Seat Occupancy

NOISE FACTORS

NOISE 1: Piece to Piece NOISE 2:Wear and tear NOISE 3: Customer Usage (Serviceability) NOISE 4: External Environment NOISE 5: System Interaction

SI1) Seat Occupancy signal short to ground

P1) Variation in mounting hole center to center distance(65) (E1.1). CU1) Usage of wrong mating coupler(E1.1,E2.1) EE1) Vibration(E1.1,E3.1)
(E4.3,E4.4).

EE2) Over/under Temperature, Humidity, Dust, SI2)Seat Occupancy signal short to

P2) Variation in housing length diamensions(69,53,77)(E1.1) CU2) Damage to unit in transit. (E1.1,E3.1)
Water (E3.1,E4.1,E4.2,E4.3,E4.4,E5.1,E6.1) battery/ignition (E4.3,E4.4)

P3) Variation in housing height dimensions(27.5)(E1.1) CU3) High/ low mounting/ mating force (E1.1) SI3) Relay output short to ground(E4.2)

SI4) Relay output short to ignition/battery

P4) Variation in thickness of housing (6)(E1.1)
(E4.2)

P5) Variation in wiring harness length(200+10) (E1.1)

SI5)Electrical transients/ stresses(Operating

voltage,current consumption in OFF mode/ON
P6) Unable to seal (Ex. Due to epoxy bubble/leakage/Crack)(E3.1) mode/monitoring mode/operating
current/current HOLD limit/current full down
limit)(E5.1)

P7) Failure of software design(E4.2)

P8)Failure of electrical circuit/ placement of wrong components

(E4.1,E4.2,E4.3,E5.1)
P9) Wrong component placement with low operating temperature range
(E5.1,E6.1)

P10) Corrosion / oxidation of terminals (E4.1,E4.2,E4.3,E4.4,E5.1)

INPUT SIGNAL SYSTEM IDEAL FUNCTION

1) Unit mounting force 1) Mounting of Engine Shut Off Controller on Vehicle

2) Connector mating force 2) Electrical mating with vehicle system

3) Battery(+ve) 3) IP resistant (IP-67)

Unit Engine Shut Off Controller With

4) Battery(-ve) 4) Functionality as per CNT000005046_SQCS_Rev00
Seat Occupancy
5) Ignition Supply (12VDC) 5) Sustainance to electrical transients / stresses

6) Seat Occupancy signal 6) To withstand Operating Temperature(-40°C to +85°C)

7) Operating Environment

8) Ground

CONTROL FACTORS REMARK ERROR STATES

Design Control/Testing and

CF1) Mounting hole center to center distance to be mentioned in drawing and customer approval to be taken (P1) E1.1) Unable to mount.
Validation
Design Control/Testing and
CF2) Housing length diamension to be mentioned in drawing and customer approval to be taken (P2) E2.1) Unable to mate with mating coupler(pin configuration)
Validation

Design Control/Testing and

CF3) Housing height diamension to be mentioned in drawing and customer approval to be taken (P3) E3.1) Failure against IP67 protection.
Validation
Design Control/Testing and
CF4) Housing thickness diamensions to be mentioned in drawing and customer approval to be taken (P4) E4.1) False reading of input signals (Seat signal)
Validation

Design Control/Testing and

CF5) Wiring harness length to be mentioned in drawing and customer approval to be taken (P5) E4.2) Relay output not working as per functionality
Validation

Design Control/Testing and

CF6) Design to meet IP67 standard (proper epoxy filling to avoid bubble/leakage) (P6). E4.3) Continous/intermittent low inputs(Seat signal).
Validation
Design Control/Testing and
CF7) Robust and reliable software design, testing and validation (P7) E4.4) Continous/intermittent high inputs(Seat signal).
Validation
Design Control/Testing and
CF8) Component are selected to meet electrical design , tolerance , simulation, testing and validation to be done (P8) E5.1) Failure against electrical sustainance.
Validation

Design Control/Software Testing

CF9) Component verification(incoming inspection) to operate in temperature range -40°C to +85°C (P9) E6.1) Fail to operate within specified temperature range( -40°C to +85°C).
and Validation

Design Control/Testing and

CF10) Plated terminals and sealed coupler used(P10)
Validation

CF11) Mating coupler/ pin configuration details are to be mentioned in drawing and customer approval to be taken (CU1) Not In DTPL Scope

Design Control/Testing and

CF12) Robust design to withstand the specified vibration and DVP to run (CU2,EE1)
Validation
Design Control/Testing and
CF13) Robust design to withstand mounting / mating force (CU3)
Validation

CF14) Design to be protected against seat occupancy signal short to ground by providing signal conditioning circuitry (SI1). Not In DTPL Scope

CF15) Design to be protected against seat occupancy signal short to battery by providing signal conditioning circuitry(SI2) Not In DTPL Scope

CF16) Design to be protected against output signal short to ground(SI3) Not In DTPL Scope

CF17) Design to be protected against output signal short to battery/Ignition(SI4) Not In DTPL Scope

CF18) Component are selected to meet specified operating voltage and current (SI5) Not In DTPL Scope

CF19) Design to operate between voltage range 10V to 16V(SI5) Not In DTPL Scope

CF20) NOT in DTPL Scope (EE2) Not In DTPL Scope

CORE TEAM
DEPARTMENT MEMBERS

R&D

QA
PE
PROD
VENDOR DEV

Format-F/ETXRD/04 REV No:00 Format Rev date- 20-06-13

 POTENTIAL FAILURE MODE AND EFFECT ANALYSIS

Design FMEA Process FMEA

System Sub-System Component Page 1 of 1 DFMEA NO:- DFMEA/ETX/ CNT000005046/00

Part Name Unit Engine Shut Off Controller With Seat Occupancy Design / Process Responsibility Prepared By
Part No. CNT000005046 R&D YH/SBP
Model Year(s) / Vehicle(s) Key Date FMEA Date (Orig.)

06.04.2017

Core Team AN,YH,SBP,AN,RM,SD,AB,ST,RT,MH,JP,PA,SK,RD,SM,SK

Classification
Item Potential Current Design Responsibilit Actions Results

Severity
R
Potential Failure Potential Effect(s) Cause(s) / Recommended y & Target
Requirement

Detect
P

Occur
Mode of Failure Mechanism(s) of Controls Actions Completion

RPN
Occ
Sev

Det
Controls Prevention N Actions taken
Function Failure Detection Date

CF1) Mounting hole

P1) Variation in center to center
Mounting on vehicle
mounting hole distance to be
Design needs to be perform Vehicle

70
7 center to center mentioned in drawing 5 5 175 R&D 7 5

2
Verification to ensure potential Testing
distance(65) and customer cause
(E1.1). approval to be taken
(P1)

CF2) Housing length

P2) Variation in diamension to be Mounting on vehicle
housing length mentioned in drawing Design needs to be perform Vehicle

70
7 5 5 175 R&D 7 5

2
diamensions(69,53 and customer Verification to ensure potential Testing
,77)(E1.1) approval to be taken cause
(P2)

CF3) Housing height

P3) Variation in diamension to be Mounting on vehicle
housing height mentioned in drawing Design needs to be perform Vehicle

70
7 5 5 175 R&D 7 5

2
dimensions(27.5) and customer Verification to ensure potential Testing
(E1.1) approval to be taken cause
(P3)

CF4) Housing
thickness
Mounting on vehicle
P4) Variation in diamensions to be
Design needs to be perform Vehicle

70
7 thickness of mentioned in drawing 5 5 175 R&D 7 5

2
Verification to ensure potential Testing
housing (6)(E1.1) and customer cause
approval to be taken
(P4)

CF5) Wiring harness

Mounting of P5) Variation in length to be Mounting on vehicle
Engine Shut Off E1.1) Unable to Degardation of wiring harness mentioned in drawing Design needs to be perform Vehicle

70
Controller on mount. primary function 7 5 5 175 R&D 7 5

2
length(200+10) and customer Verification to ensure potential Testing
Vehicle. (E1.1) approval to be taken cause
(P5)

CF11) Mating coupler/

pin configuration
Mating coupler
CU1) Usage of details are to be
Design needs to be used

14
7 wrong mating mentioned in drawing 2 1 14 PE 7 1

2
Verification at end of line
coupler(E1.1,E2.1) and customer
testing
approval to be taken
(CU1)

CF12) Robust design

CU2) Damage to to withstand the
Product Product

70
7 unit in transit. specified vibration 5 5 175 Product validation QA 7 5

2
validation validation
(E1.1,E3.1) and DVP to run
(CU2,EE1)

CF13) Robust design

CU3) High/ low
to withstand Mating coupler Product

70
7 mounting/ mating 5 Proto Validation 5 175 QA 7 5

2
mounting / mating needs to be used validation
force (E1.1)
force (CU3)

CF12) Robust design

to withstand the
EE1) Product Product

70
7 specified vibration 5 5 175 Product validation QA 7 5

2
Vibration(E1.1,E3.1) validation validation
and DVP to run
(CU2,EE1)

E2.1) Unable to CF11) Mating coupler/

pin configuration details Mating coupler
Electrical mate with CU1) Usage of wrong
Degardation of are to be mentioned in Design needs to be used
mating with mating 14 PE 14
7 mating 2 1 7 1
2

primary function drawing and customer Verification at end of line

vehicle system coupler(pin coupler(E1.1,E2.1)
approval to be taken testing
configuration) (CU1)

P6) Unable to seal CF6) Design to meet

(Ex. Due to epoxy IP67 standard (proper Product Product
70

7 5 5 175 Product validation QA 7 5

2

bubble/leakage/Cr epoxy filling to avoid validation validation

ack)(E3.1) bubble/leakage) (P6).

CF12) Robust design

CU2) Damage to to withstand the
Product Product
70

7 unit in transit. specified vibration 5 5 175 Product validation QA 7 5

2

validation validation
(E1.1,E3.1) and DVP to run
(CU2,EE1)
E3.1) Failure
3) IP resistant Degardation of
against IP67
(IP-67) primary function
protection.
CF12) Robust design
to withstand the
EE1) Vibration Product Product
70

7 specified vibration 5 5 175 Product validation QA 7 5

2

(E1.1,E3.1) validation validation

and DVP to run
(CU2,EE1)

EE2) Over/under
Temperature,
Humidity, Dust, CF20) NOT in DTPL NOT in DTPL
7 - - - - - -
Water Scope (EE2) Scope
(E3.1,E4.1,E4.2,E4.
3,E4.4,E5.1,E6.1)
 CF8) Component are
P8)Failure of Design Design
selected to meet
electrical circuit/ verification, verification,
electrical design ,
placement of Component Component Proto

70
7 tolerance , 5 5 175 R & D, QA 7 5

2
wrong components verification(line verification(line Validation
simulation, testing
(E4.1,E4.2,E4.3,E5. assembly) & assembly) & Proto
and validation to be
1) Proto validation validation
done (P8)

E4.1) False P10) Corrosion /

reading of input Degardation of oxidation of CF10) Plated
signals (Seat primary function Product Product

70
7 terminals terminals and sealed 5 5 175 Product validation QA 7 5

2
signal) validation validation
(E4.1,E4.2,E4.3,E4. coupler used(P10)
4,E5.1)

EE2) Over/under
Temperature,
Humidity, Dust, CF20) NOT in DTPL NOT in DTPL
7 - - - - - -
Water Scope (EE2) Scope
(E3.1,E4.1,E4.2,E4.
3,E4.4,E5.1,E6.1)

CF7) Robust and Software

P7) Failure of Design
reliable software Software testing testing,vehicl

70
7 software 5 verification & 5 175 R&D 7 5

2
design, testing and and validation e testing and
design(E4.2) Proto validation
validation (P7) validation

CF8) Component are

P8)Failure of Design Design
selected to meet
electrical circuit/ verification, verification,
electrical design ,
placement of Component Component Proto

70
7 tolerance , 5 5 175 R & D, QA 7 5

2
wrong components verification(line verification(line validation
simulation, testing
(E4.1,E4.2,E4.3,E5. assembly) & assembly) & Proto
and validation to be
1) Proto validation validation
done (P8)

P10) Corrosion /
oxidation of CF10) Plated
Product Product

70
7 terminals terminals and sealed 5 5 175 Product validation QA 7 5

2
validation validation
(E4.1,E4.2,E4.3,E4. coupler used(P10)
4,E5.1)
E4.2) Relay
output not Degardation of
working as per primary function
functionality EE2) Over/under
Temperature,
1.Mounting of Humidity, Dust, CF20) NOT in DTPL NOT in DTPL
7 - - - - - -
Engine Shut Off Water Scope (EE2) Scope
Controller on (E3.1,E4.1,E4.2,E4.
Vehicle. 3,E4.4,E5.1,E6.1)
2.Electrical
mating with
vehicle system
3. IP resistant CF16) Design to be
(IP-67) SI3) Relay output
protected against NOT in DTPL
4.Functionality as 7 short to - - - - - -
output signal short to Scope
per ground(E4.2)
ground(SI3)
CNT000005046_
SQCS_Rev00
5.Sustainance to
electrical
transients /
stresses. CF17) Design to be
SI4) Relay output
6. To withstand protected against NOT in DTPL
7 short to - - - - - -
Operating output signal short to Scope
ignition/battery (E4.2)
Temperature(- battery/Ignition(SI4)
40°C to +85°C) 4) Functionality
as per
CNT000005046
_SQCS_Rev00 CF8) Component are
P8)Failure of Design Design
selected to meet
electrical circuit/ verification, verification,
electrical design ,
placement of Component Component Proto

50
5 tolerance , 5 5 125 R & D, QA 5 5

2
wrong components verification(line verification(line validation
simulation, testing
(E4.1,E4.2,E4.3,E5. assembly) & assembly) & Proto
and validation to be
1) Proto validation validation
done (P8)

P10) Corrosion /
oxidation of CF10) Plated
Product Product

50
5 terminals terminals and sealed 5 5 125 Product validation QA 5 5

2
validation validation
(E4.1,E4.2,E4.3,E4. coupler used(P10)
4,E5.1)

EE2) Over/under
E4.3)
Temperature,
Continous/interm
Degradation of Humidity, Dust, CF20) NOT in DTPL NOT in DTPL
ittent low 5 - - - - - -
secondary function. Water Scope (EE2) Scope
inputs(Seat
(E3.1,E4.1,E4.2,E4.
signal).
3,E4.4,E5.1,E6.1)

CF14) Design to be
protected against
SI1) Seat
seat occupancy signal Design
Occupancy signal Design verification
10

5 short to ground by 2 verification & 1 10 R&D 5 1

2

short to ground & Proto validation

providing signal Proto validation
(E4.3,E4.4).
conditioning circuitry
(SI1).

CF15) Design to be
SI2)Seat protected against
Occupancy signal seat occupancy signal Design
Design verification
10

5 short to short to battery by 2 verification & 1 10 R&D 5 1

2

& Proto validation

battery/ignition providing signal Proto validation
(E4.3,E4.4) conditioning
circuitry(SI2)

P10) Corrosion /
oxidation of CF10) Plated
Product Product
50

5 terminals terminals and sealed 5 5 125 Product validation QA 5 5

2

validation validation
(E4.1,E4.2,E4.3,E4. coupler used(P10)
4,E5.1)

EE2) Over/under
Temperature,
Humidity, Dust, CF20) NOT in DTPL NOT in DTPL
5 - - - - - -
Water Scope (EE2) Scope
(E3.1,E4.1,E4.2,E4.
E4.4) 3,E4.4,E5.1,E6.1)
Continous/interm
Degradation of
ittent high
secondary function.
inputs(Seat
signal).
 E4.4)
Continous/interm
Degradation of
ittent high
secondary function.
inputs(Seat CF14) Design to be
signal). protected against
SI1) Seat
seat occupancy signal Design
Occupancy signal Design verification

10
5 short to ground by 2 verification & 1 10 R&D 5 1

2
short to ground & Proto validation
providing signal Proto validation
(E4.3,E4.4).
conditioning circuitry
(SI1).

CF15) Design to be
SI2)Seat protected against
Occupancy signal seat occupancy signal Design
Design verification

10
5 short to short to battery by 2 verification & 1 10 R&D 5 1

2
& Proto validation
battery/ignition providing signal Proto validation
(E4.3,E4.4) conditioning
circuitry(SI2)

CF8) Component are

P8)Failure of Design Design
selected to meet
electrical circuit/ verification, verification,
electrical design ,
placement of Component Component Proto

60
6 tolerance , 5 5 150 R & D, QA 6 5

2
wrong components verification(line verification(line Validation
simulation, testing
(E4.1,E4.2,E4.3,E5. assembly) & assembly) & Proto
and validation to be
1) Proto validation validation
done (P8)

P9) Wrong
CF9)component
component
verification(incoming Component Component
placement with

12
6 inspection) to operate 2 verification(line 1 12 verification(line QA 6 1

2
low operating
in temperature range assembly) assembly)
temperature range
-40°C to +85°C (P9)
(E5.1,E6.1)

P10) Corrosion /
oxidation of CF10) Plated
Product Product

60
6 terminals terminals and sealed 5 5 150 Product validation QA 6 5

2
validation validation
(E4.1,E4.2,E4.3,E4. coupler used(P10)
4,E5.1)

5) Sustainance Degradation of
E5.1) Failure
to electrical secondary function or
against electrical EE2) Over/under
transients / Loss of secondary
sustainance. function Temperature,
stresses.
Humidity, Dust, CF20) NOT in DTPL NOT in DTPL
6 - - - - - -
Water Scope (EE2) Scope
(E3.1,E4.1,E4.2,E4.
3,E4.4,E5.1,E6.1)

CF18) Component are

selected to meet Design
SI5)Electrical Design verification Proto

60
6 specified operating 5 verification & 5 150 R&D 6 5

2
transients/ & Proto validation Validation
voltage and current Proto validation
stresses(Operating
(SI5)
voltage,current
consumption in
OFF mode/ON
mode/monitoring
mode/operating
current/current
HOLD limit/current
full down limit)
(E5.1)
CF19) Design to
Design
operate between Design verification Proto

60
6 5 verification & 5 150 R&D 6 5

2
voltage range 10V to & Proto validation Validation
Proto validation
16V(SI5)

P9) Wrong
CF9) Component
component
verification(incoming Component Component
placement with

12
6 inspection) to operate 2 verification(line 1 12 verification(line QA 6 1

2
low operating
in temperature range assembly) assembly)
temperature range
-40°C to +85°C (P9)
(E5.1,E6.1)
E6.1) Fail to
6) To withstand operate within Degradation of
Operating specified secondary function or
Temperature(- temperature Loss of secondary
40°C to +85°C) range( -40°C to function
+85°C).

EE2) Over/under
Temperature,
Humidity, Dust, CF20) NOT in DTPL NOT in DTPL
6 - - - - - -
Water Scope (EE2) Scope
(E3.1,E4.1,E4.2,E4.
3,E4.4,E5.1,E6.1)

Note:- A) Classification Severity Symbol Class Symbol Used PARAMETERS CONSIDERED

i) Critical to Safety /Regulatory (Ö)
10 or 9 Critical CUST. DRG. SPECS
Requirement
ii) Critical to Fit and Function 8,7 or 6 Major CUST.WARRANTY/ LINE REJ. (Ö)

iii) Appearance/Key Instruction 5,4,3,2 or1 Key instruction INTERNAL LINE REJ. (Ö)

Note:- B) Action to be Taken if DESIGN/PROCESS REVIEW MEETING INPUTS (Ö)

1. Sev 9 ,10 & RPN ≥ 50 IMPLICIT NEEDS (Ö)

2. Top 3 RPN TECHNICAL KNOW HOW (Ö)

Format no. - F/ETXRD/04-a Rev no - 00 Issue date - 19-03-2013

E8.1) Unit failures in transients / electrical stresses
E9.1) Failure against IP67/Vibration proof
E10.1) Failure to withstand tightning screw torque
4.5Nm