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TABLE - 1

Issued By :
Complete Final Assembly / Sub Assembly / Rubber Parts from BIN that are going into Final Assembly with SC CC Characteristics

BI / SP GP / 09 - PFMEA - April 2010

Warrants immediate action with specified time targets to switch over to YELLOW / GREEN
ZONE

Warrants action at the earliest to switch over to GREEN ZONE

OCCURRENCE

Actions to be Initiated

Zone

SEVERITY
Criteria : Severity of Effect on Product
(Customer Effect)

Potential failure mode affects safe


vehicle operation and / or involves
noncompliance with government
regulation without warning
Potential failure mode affects safe
vehicle operation and / or involves
noncompliance with government
regulation with warning

Effect

Criteria : Severity of Effect on Process


(Manufacturing / Assembly Effect)

May endanger operator (machine or


Faiulre to Meet assembly) without warning
Safety and / or
Regulatory
Requirements May endanger operator (machine or
assembly) with warning

100% of product may have to be


Loss or
scrapped. Line shutdown or stop ship
Degradation of
A portion of the production run may
Primary
Degradation of primary function
have to be scrapped. Deviation from
Function
(vehicle operable, but at reduced level
primary process including decreased
of performance)
line speed or added manpower

Degradation of secondary function


(vehicle operable, but comfort /
convenience functions at reduced
level of performance )

Faiulre to Meet
Safety and / or
Regulatory
Requirements

>=100

50

20

10

0.5

0.1

0.01

1 in

>=10

20

50

100

500

2,000

10,000

100,000

10

0.2

0.05

0.01

0.001

Failure is
1,000,000 eliminated
through
preventive
0.0001
control

PPM

1,00,000

50,000

20,000

10,000

2,000

500

100

10

Likelihood
of Failure

Very High

RANK

Moderate

Low

Very Low

10

100% of production run may have to


Loss or
be reworked off line and accepted
Degradation of
Secondary
A portion of the production run may
Function
have to be reworked off line and
accepted

Major
Disruption

Significant
Disruption

5
Moderate
Disruption

YELLOW ZONE

Appearance or Audible Noise, Vehicle


operable, item does not conform and
noticed by most customers (>75%)

100% of production run may have to


be reworked in satiation before it is
processed

Appearance or Audible Noise, Vehicle


operable, item does not conform and Annoyance
noticed by most customers (50%)

A portion of the production run may


have to be reworked in station
before it is processed

Appearance or Audible Noise, Vehicle


operable, item does not conform and
noticed by discriminating customers
(<25%)

Slight inconvenience to process,


operation, or operator

Minot
Disruption

No discernible effect

No Effect

No discernible effect

10

High

<0.001

RED ZONE

Loss of primary function (vehicle


inoperable, does not affect safe
vehicle operation)

Loss of secondary function (vehicle


operable, but comfort / convenience
functions inoperable)

Effect

Per 1000

No Effect

GREEN ZONE