FAILURE MODE AND EFFECTS ANALYSIS CUSTOMER DESCRIPTION PART No. TOOL No. MATERIAL NYLON 6.

6 Black POTENTIAL EFFECTS OF FAILURE SEV POTENTIAL CAUSES OF FAILURE OCC CO-ORDINATOR FMEA DATE PROJECT SHEET 1 D CASH

PROCESS POTENTIAL DESCRIPTION FAILURE MODE

INCOMING GOODS

INCORRECT MATERIAL

NO MATERIAL, PARTS UNAVAILABLE

9 MATERIAL ORDERED INCORRECTLY

INCOMING GOODS

INCORRECT MATERIAL

NO MATERIAL, PARTS UNAVAILABLE

9 WRONG MATERIAL RECEIVED

INCOMING GOODS

WRONG GRADE OF MATERIAL

NO MATERIAL, PARTS UNAVAILABLE

9 SUPPLIER MISTAKE

MATERIAL HANDLING

WRONG MATERIAL RELEASED TO SHOP FLOOR

NO MATERIAL, PARTS UNAVAILABLE

MATERIAL 9 HANDLING PROCEDURE NOT FOLLOWED

MATERIAL HANDLING

WRONG MATERIAL RELEASED TO SHOP FLOOR

PART WILL NOT COMPLY WITH CUSTOMER SPEC. PART WILL BE DIFFICULT TO MOULD

MATERIAL 8 HANDLING PROCEDURE NOT FOLLOWED

RE MODE AND EFFECTS ANALYSIS D CASH SUBSCRIBERS

CURRENT CONTROLS ORDER PLACED AGAINST CUSTOMER SPECIFICATION ON MRP SYSTEM

DET

RISK RECOMMENDED AREA ACTION RESULTS PRIORITY ACTIONS INDIVIDUAL ACTIONS SEV NUMBER RESPONSIBLE TAKEN

18 RETAIN CURRENT CONTROLS

#REF!

SUPPLIER IS APPROVED AND THEIR SYSTEMS CONFORM TO REQUIREMENT

18

#REF!

SUPPLIER IS APPROVED AND THEIR SYSTEMS CONFORM TO REQUIREMENT

36

#REF!

MATERIAL RELEASED ACCORDING TO JOB SHEET

18

#REF!

MATERIAL RELEASED ACCORDING TO JOB SHEET

80

#REF!

ACTION RESULTS OCC

DET

RPN

#REF!

#REF!

#REF!

#REF!

#REF!

#REF!

#REF!

#REF!

#REF!

#REF!

#REF!

#REF!

#REF!

#REF!

#REF!

FAILURE MODE AND EFFECTS ANALYSIS CUSTOMER DESCRIPTION PART No. TOOL No. MATERIAL NYLON 6.6 Black POTENTIAL EFFECTS OF FAILURE SEV POTENTIAL CAUSES OF FAILURE OCC CO-ORDINATOR FMEA DATE PROJECT SHEET 1 D CASH

PROCESS POTENTIAL DESCRIPTION FAILURE MODE

MOULDING

Flowlines or Gas

POOR COSMETICS

9 RIBS TOO THICK

10

FLASH

POOR FIT & FUNCTION

10 WEAR ON CLIPS

GASSING

POOR COSMETICS

8 GAS TRAP INSUFFICIENT VENTING

Silvering

POOR COSMETICS

8 INCORRECT PROCESSING

SHORTING ON PIPS SWITCH WILL NOT FUNCTION

10 GASSING

8 OVERHEATING IN BARREL

MATERIAL

DRIED TOO HOT / LONG

DEGRADED

CTS ANALYSIS 0 SUBSCRIBERS

CURRENT CONTROLS

DESIGN IS GAS TRAP

DET RISK RECOMMENDED PRIORITY ACTIONS NUMBER cHANGE DESIGN IN SPLITS OR ADD STYLING GROOVE / RECESS TO GIVE AREA TO VENT ONTO. 10 900

AREA INDIVIDUAL RESPONSIBLE

LUCAS/MPC FEP

BUSINESS UNIT OPERATOR INSPECTION NORMAL TOOL SERVICE 4 160 KEEP SPARES FOR CLIP INSERTS

FLASH ON CLIPS - FEP TO CORRECT 2 48

FEP

EVALUATE ON 1st TRIAL VENT DOWN CENTRE PIN

0 RETAIN CURRENT CONTROLS 2 64 RETAIN CURRENT CONTROLS 150 ENSURE VENTING IS ENOUGH TO PREVENT BUILD UP OR BLOCKED VENTS WHICH COULD CAUSE SHORTING LATER 64 RETAIN CURRENT CONTROLS

BUSINESS UNIT

1ST OFF APP & INPROCESS CHECKS VENTING ON CENTRE PIN

BUSINESS UNIT

FEP

1ST OFF APP & INPROCESS CHECKS SETTING

BUSINESS UNIT

SHEETS MATL SPECS

ACTIONS TAKEN

ACTION RESULTS SEV OCC DET RPN

GA'S APPROVED SAMPLES OK

36

32

OK

OK

10

20

CUSTOMER DESCRIPTION PART No. TOOL No. MATERIAL PROCESS DESCRIPTION NYLON 6.6 Black POTENTIAL FAILURE MODE POTENTIAL EFFECTS OF FAILURE SEV

MOULDING CHARACTERISTICS DIMENSIONAL

POOR FIT & FUNCTION

10

GENERAL

DAMAGE

DEFECTS PRODUCED OR SHIPPED

10

FAILURE MODE AND EFFECTS ANALYSIS CO-ORDINATOR FMEA DATE PROJECT SHEET 1 D CASH

POTENTIAL CAUSES OF FAILURE

OCC

CURRENT CONTROLS

DET RISK PRIORITY NUMBER

TOOL SIZES / DISTORTION

8 EVALUATE ON 1st TOOL TRIAL SPC FIXTURES

320

INADEQUATE PACKAGING Handling

5 CARTONS AND TRAYS TBA

250

SUBSCRIBERS

RECOMMENDED ACTIONS

AREA INDIVIDUAL ACTIONS RESPONSIBLE TAKEN MPC MPC FEP LUCAS MPC MPC \ LUCAS COMPLETE COMPLETE WIP COMPLETE ORDERED GA'S APPROVED

ACTION RESULTS SEV OCC DET RPN

100% ISIR AT CS PRECISION PPK/CMK STUDIES MODIFY TOOL FOR CAPAB. UPDATE DRAWINGS TRIAL NEW MATERIALS PURCHASE FIXTURES

32

FINALISE PACKAGING REQUIREMENT

LUCAS / MPC

WIP VAC-FORM TRAYS

40