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WHFM/01/01

PROCESS FAILURE MODE AND EFFECT ANALYSIS (P-FMEA) Rev.Date : 24/02/08

FMEA Key Date: 10-Dec-08


MODEL NAME: Landi Ranzo PROCESS RESPONSIBILITY: Thal Engineering Limited MODEL YEAR / VEHICLE: 2008
MODEL NO.: 273 & 274 CUSTOMER AFFECTED: Landi Ranzo CORE TEAM: Sajida Mateen, Adeel Siddiqui
FMEA Date: 18-Sep-08 FMEA Revision Date: - Rev. # NA
Action Remarks

Occurrence

Detection
Severity

Occurrenc

Detection
Severity
Responsibility &

Class
Potential Cause(s) / Recommended Target

RPN
Process Process Function
Potential Failure Mode Potential Effect(s) of Failure Current Process Controls Action

RPN
Completion
No. Requirements Mechanism(s) Actions

e
Date Taken

In Coming Material received on Wrong In Coming Inspection as per Control


Unacceptable for next operation
Wires donot match the required tag Plan
3 2 3 18
specs In Coming Inspection as per Control
Line Delay Wrong Shipment from Supplier
Plan
1 RECEIVING
Unacceptable for next operation In Coming Inspection.
Sheet Metal Parts out of Spec 3 Wrong Parts Shipped by Supplier 2 3 18
Line Delay SOP at all Production Process, FO
Rubber & Plastic Parts Out of Unacceptable for next operation Wrong Parts Shipped by Supplier In Coming Inspection.
3 2 3 18
Spec Line Delay Parts Got defromed/ damaged SOP at all Production Process, FO
Sub Assembly Not Possible Wrong wire specs on the Job card

Cut wire not the One on the Time loss Job card not readable FO Procedure, QA Inspection, Operator
4 3 3 36
drawing (Wrong Wire) Inspection
Wrong Job Card Distributed at the
CUTTING/ Material Wastage
2 machine
STRIPPING
Wire Length Short or Longer than Assembly Not Possible Wrong Job Cards Used FO Procedure, QA Inspection as Per
4 2 3 24
the Spec limits Control Plan
Extra Wires result in wrong assembly Job Card Not followed
Crimping Not Possible Wrong data fed in machine FO Procedure, QA Inspection
Wrong Stripping 4 2 3 24
Unacceptable for next operation Job Card Not Followed FO Procedure, QA Inspection
Job Cards, Set Up procedure, FO
Terminal will not lock properly Wrong Specs
Procedure, Sub Assembly SOP
Wrong terminal crimp, not Job Cards, Set Up procedure, FO
Can not perform the intended function 5 Wrong Terminal reel on the machine 2 3 30
according to Job Card Procedure, Sub Assembly SOP
Wrong Job Card attached with the Job Cards, Set Up procedure, FO
termianl reverse
bunch of cut wires Procedure, Sub Assembly SOP

Crimping Specs based on Pull Test Spec Cards based on Pull Test, Setup
Insulation Barrel Broken Cannot perform the intended function 6 3 4 72 Japanese Crimping QA & R&D Team Japanese 6 1 4 24
doesn’t guarantee proper crimping inspection, QA FO Inspections.
Specs to be Crimping
Implemented instead Specs from
3 Crimping Chances of Wires coming loose from Crimping Specs based on Pull Spec Cards as per Japanese Specs, of Pull Test based FAS
Damaged wires, Bite on Wires 6 3 4 72 Crimping Specs. 31-Mar-08 implemented 6 1 4 24
Terminal Testdoesn’t guarantee proper crimping Setup inspection, QA FO Inspections.

Strands not visible from the point Chances of Wires coming loose from Crimping Specs doesn’t guarantee Spec Cards as per Japanese Specs,
5 2 3 30
of insulation. Terminal proper crimping Setup inspection, QA FO Inspections.

Strands not visible post crimping Chances of Wires coming loose from Crimping Specs doesn’t guarantee Spec Cards as per Japanese Specs,
5 2 3 30
point Terminal proper crimping Setup inspection, QA FO Inspections.

Terminals covered with special bags


Terminals Get Oxidized Cannot perform the intended function 4 Terminals are exposed to air 2 3 24
when not in use.
Sub Assembly Inspection, FO, ECT
Cross circuit In correct Drawing
Process
Wrong Insertion 4 2 3 24
Sub Assembly Inspection, FO, ECT
Short Circuit Connector Direction. Not followed
Process
Assembly instructions, drawing not Sub Assembly Inspection, ECT
4 SUB ASSEMBLY Wire Miss Cannot perform the intended function 4
followed.
2
Process.
2 16

Terminal not locked properly Terminal reverse 5 Insert-Click-Pull not followed 2 Insert, Click and Pull SOP, ECT 3 30

Wire/ Insulation damaged Unacceptable for next operation 4 Mis Handling. 3 Operator's Instructions, FO, FVI. 3 36

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Sub Assembly Inspection, FO, ECT
Cross circuit In correct Drawing
Process
Wrong Insertion 4 2 2 16
Sub Assembly Inspection, FO, ECT
Short circuit Connector Direction. Not followed
Process
Jigs, Visual Aids, Final Visual
Not usable at customer end No error proofing at the station
Inspection.
Component Missing 4 4 3 48
Jigs, Visual Aids, Final Visual
Product failure at ECT Material short supply on line
Inspection.
FINAL Dirt on Connectors Cannot confirm to the Quality Standards 3 Marks of Fabric Tape 4 Rework cards on reowrk harness 2 24
5
ASSEMBLY
Visual
Visual Controls on All Production & QA (6
Wrong Tape Used Cannot confirm to the Quality Standards 5 Tape Types not Clear to Operator 4 Shopping List and visual inspections 4 80 Controls 5 1 3 15
Boards Needed Dec. 2007)
Installed
Proper Tools not used for cutting the
Tie Clip Band Not cut as oer spec Not Acceptable for next Process 3 4 Tyton Guns with proper torques. 3 36
bands
Product Handling SOP, FO, QA
Wire/ Insulation damaged Unacceptable for next operation 4 Damaged due to mis handling. 3 4 48
Inspections, FVI
Wire lenghts not as per drawing/
Unable to Assemble. 4 Job Card not followed. 4 SOP, QA Inspection, FVI 3 48
drawing board

Harness delivered to the next sec. Product Quality/ functionality is not ECT Pass Tape Check on next
4 Name Sheet missing. 2 5 40
Without ECT assured operation 100%

Pass harness moved without


Second time ECT to be performed 3 Stamp not available at the station 2 Stamp Check on next operation 100% 5 30
ELECTRIC stamp
6 CONTINUITY
TEST (ECT) Harness move to the next section
Harness may be sent to the OEM. 5 Harnesses almost identical 2 Stamp Check on next operation 100% 4 40
with wrong name sheet.

Product Quality/ functionality is not ECT unable to detect the wrong Computer software doent issue a pass
ECT passed a wrong insertion 6 2 2 24
assured insertion. sheet

Cant not detect Exterior parts Visual Aids, Jigs, Master Sample,
Harness not usable by customer 6 Master sample, SOP Not Followed 1 5 30
missing. Training

Visual Aids, Jigs, Master Sample,


Cant detect Branch length short Harness will not fit properly into vehicle 6 Master sample, SOP Not Followed 1 5 30
Training
FINAL VISUAL
7
INSPECTION (FVI)
Visual Aids, Jigs, Master Sample,
Cant Detect Wrong fuse insertion. Fuse or devices not working into vehicle 6 Master sample, SOP Not Followed 1 5 30
Training

Cant Detect Wrong exterior part Harness will not fitted properly into Visual Aids, Jigs, Master Sample,
6 Master sample, SOP Not Followed 1 5 30
mounting. vehicle Training

Visual Aids, igs, Process & Product


Cant Catch a wire/ PVC damage Short circuit mal Functioning of system 6 Safe Handling procedures not followed 1 5 30
Audits, Pre-Ship Audits.

PRE DELIVERY
8 INSPECTION Unable to Catch a Wrong name Visual Aids, igs, Process & Product
(PDI) Harness can mount wrong vehicle 6 Check & Mark not done 1 5 30
sheet Audits, Pre-Ship Audits.

Unable to determine a Wrong/ Harness will not fitted properly into Critical parts are not visually checked & Visual Aids, igs, Process & Product
6 1 5 30
Damaged/ Missing Par vehicle marked. Audits, Pre-Ship Audits.

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Pre-Ship Audits
Parts Damaged during Shipment 5 Insufficient training 2 5 50
SOP, Training and training Audits
Un-Safe Packing
Proper training of Operators
Parts get damaged at customer ware
5 Proper Packing Material Not Used 2 5 50
house during handling.
Pre-Ship Audits
9 PACKAGING
Pre-Ship Audits
Wonrg Part Packing Delay on customers' Line 5 Insufficient training 2 5 50
Training Audits

Pre-Ship Audits
Wrong Quantity sent to customer Delay on customers' Line 5 Insufficient training 2 5 50
Training Audits

Periodic Product Audit at Dispatch


Delayed part to line Insufficient training
VisuaL aids
Wrong labeling 6 2 4 48
Periodic Product Audit at Dispatch
10 DISPATCH Wrong part to line Label Printer malfunction
Lay out Audit

SOP & Training


Incorrect Order quantity on the dispatch
Incorrect Quantity of Boxes Delay on Line 5 1 4 20
sheet
Dispatch Checklist.

** Significant
Characteristics

Prepared By: Checked By: Approved By:

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