【正文】 r to detect presence of ponents, 100% inspection by operator 7 90 Process Function/ Requirements Potential Failure mode Potential effect of failure SEV C l a s s Potential Cause (s) Mechanism of failure Occur Current Process Controls Prevention Current Process Controls Detection Detec RPN Rem.actions Resp. Target date Action taken SEV OCC DET RPN Adding studs on grille Machine fail to add studs on grille Missing studsto customer, no build situation 8 Interupt light curtain during adding studs on grille 2 None Sensor detection of studs on grille, but operator can pass process step 6 72 Operator can’t pas process step by PLC sequence control to operator Tech Complete 8 2 3 48 Previous failure mode: 100% Operator inspection vary from 4 to 7? Missing studs is an affect from a failure mode! root cause is not defined Machine failure or malfunction Assembly operation is a process step but is not defined Process Function/ Requirements Potential Failure mode Potential effect of failure SEV C l a s s Potential Cause (s) Mechanism of failure Occur Current Process Controls Prevention Current Process Controls Detection Detec RPN Res Resp. Target date Action taken SEV OCC DET RPN Injection mold Grille Flash Poor fit function Poor appearance Visually unacceptable 6 Process parameters Mold damage Improper seal New/repaired mold 4 Mold PM Set up verification 100% inspect First piece approval 6 108 Process Function/ Requirements Potential Failure mode Potential effect of failure SEV C l a s s Potential Cause (s) Mechanism of failure Occur Current Process Controls Prevention Current Process Controls Detection Detec RPN Rens Resp. Target date Action taken SEV OCC DET RPN Injection mold Grille Mold platen not paralel Flash 6 Tie bars not accurate 2 PM No detection 6 72 None HE Remember: Severity between 58 with bination of occurrence 410 are HE failure modes Previous failure mode: 100% detection was a 7 Remember: Flash is an effect from a failure mode To much causes: Mold damage=2, Process parameter= 3, New/repaired mold=1 Process Function/ Requirements Potential Failure mode Potential effect of failure SEV C l a s s Potential Cause (s) Mechanism of failure Occur Current Process Controls Prevention Current Process Controls Detection Detec RPN Rens Resp. Target date Action taken SEV OCC DET RPN 67 Cam Surface defects Visual dissatisfaction 3 A:Padmark BMaterial handling CRough surface of die 2 Awork instruction for inspection and process BOperator training CPM program A1st piece sample BFinal audit CCheck fixture DDock audit Erun check part 6 108 None Process Function/ Requirements Potential Failure mode Potential effect of failure SEV C l a s s Potential Cause (s) Mechanism of failure Occur Current Process Controls Prevention Current Process Controls Detection Detec RPN Rens Resp. Target date Action taken SEV OCC DET RPN Cam process Material handling Severe surface defects 6 HE Operator hit part to another object during loading/unloading 4 PM program No detection on operarot could potentia hit part 9 216 Protect were the operator could damaged Tech plete 6 2 4 48 Severity on surface defects should have higher ranking Similar detections are a 7: Visual inspection should be a 8 Surface defects are effects from a failure mode To much causes: Padmark=2, Material handling= 4 Rough surface of die= 2 FMEA building block Building block system Uses the premises that: ? Difference from part to part are minimal ? Molding is molding, plating is plating, paint is paint,etc. ? Process improvements to part ABC will likely apply to part XYZ ? Focuses on the exception, what scares or concern us about the new product. ? Don’t focus on the routine things we do everyday Building blocks develop for core processes: ? Molding ? Plating ? Paint ? Resist Top Coat ? Assembly (if possible) ? Receiving ? Secondary equipment Benefits ? Uses true process owners to define failures, effects and countermeasures – Capture Internal External Issues – Promotes standardization and best practices between Guardian facilities – MHD and EVV should have the same core PFMEA’s ? Global documentation – Focus on process improvement – Problem solving ? Linked PFMEA, Controls Plans and Process Flow is a requirement. Trim Receiving Mold Paint Plate Snap on (emblem) Handling/Transport Storage Resist Top Coat Core Processes that have Building Block APQP developed Weld Assemble Building Block APQP Projects for Trim Receiving Mold Weld Paint Topcoat Resist Plate Snap On (Emblem) Handling/Transport Storage Part Specific APQP DFMEA, PFMEA and Control Plan for Plated Grill with Emblem Pick/Reference all applicable core process PFMEA/Control Plans. Review part for items not covered by core process documentation and either: 1) Amend core documentation 2) Include in Part Specific documentation. 3) Create a new core process FMEA/CP Assemble