POTENTIAL FAILURE MODE AND EFECTS ANALYSIS

PART NO : 33 18 202 90 FMEA NUMBER: 940

ITEM : Bearing Bush (PROCESS FMEA) Prepared by : CFT LEADER
Model Year(s)/Vehicles(s) : Key Date : 26.03.2010 FMEA Date (org): 26.03.2010
Core Team : CFT MEMBERS Process Responsibility: CFT LEADER FMEA Date (rev): 10.10.2018 ( K)

Current Current Responsibility & Action results

Potential Potential Potential Causes

Occur

RPN
Detec
Class
Sev
Process process Recommended Target
Process Failure Effect(s) of Mechanism(s) of
Controls controls Action(s) Completion

RPN
Occ
Sev

Det
Mode failure failure Action taken
prevention detection Date

INT : Difficult Improper Supply

No identifi- Receiving
in selection of 4 of RM by 2 Nil 5 40
cation. Inspection
material. supplier.

Improper Supply
1R Damages on INT: Tools are Receiving
4 of RM by 2 Nil 5 40
INCOMING strips damaged. Inspection
supplier.
INSPECTION
(Receive the
materials with
proper Thickness INT: Tools are Uneven size of Receiving
4 3 Nil 5 60
identification oversize damaged Strip Inspection
and correct
dimensions

Thickness INT: Less stamp Uneven size of Receiving

3 3 Nil 5 45
undersize impression Strip Inspection

Burr, dent &

Receiving
Appearance Visual defects 2 flame mark on 2 Nil 5 24
Inspection
steel surface

ABBREVATIONS: INT: INTERNAL, EXT: EXTERNAL ACTION PLAN TO BE CARRIED OUT IF THE SEVERITY > 8 & RPN LEVEL IN DESCENDING ORDER
 POTENTIAL FAILURE MODE AND EFECTS ANALYSIS
PART NO : 33 18 202 90 FMEA NUMBER: 940
ITEM : TO PERTAINING PARTS (PROCESS FMEA) Prepared by : CFT LEADER
Model Year(s)/Vehicles(s) : Key Date : 26.03.2010 FMEA Date (org): 26.03.2010
Core Team : CFT MEMBERS Process Responsibility: CFT LEADER FMEA Date (rev): 10.10.2018 ( K)
Potential Current Current Responsibility Action results
Process Potential Potential

Occur

RPN
Detec
Class
Sev
Causes Process process Recommended & Target
Function Failure Effect(s) of
Mechanism(s) of Controls controls Action(s) Completion

RPN
Occ
Sev

Det
Requirement Mode failure Action taken
failure prevention detection Date
First off
Blank
INT: Outside dia Coil Feeder &
Length 5 2 Servo Feeder 6 60
oversize. Incorrect setting in-process
Oversize.
inspection.
First off
Blank
INT: Outside dia Coil Feeder &
Length 8 2 Servo Feeder 6 96
undersize Incorrect setting in-process
Undersize.
inspection.
EXT:1. Less oil
Groove
flow cause oil Tool History First off &
wall Worn out of
15 starvation 2. 7 2 Card inprocess 6 60
thickness coining tool
STAMPING, Shaft will be Maintained inspection
oversize
COINING & wear
BLANKING
Groove
EXT: 1. Excess First off &
wall Incorrect ram
oil flow 5 2 NA inprocess 6 60
thickness setting
2. Oil leakage inspection
undersize
First off
EXT:1. Less oil
Groove Incorrect Progressive &
flow cause oil 8 2 6 96
shift location Tool in-process
starvation
inspection.
First off
Improper EXT: Difficult in &
Incorrect stamp
Stamping identifying the 2 1 NA in-process 6 12
part setting
depth Part No. inspection.
ABBREVATIONS: INT: INTERNAL, EXT: EXTERNAL ACTION PLAN TO BE CARRIED OUT IF THE SEVERITY > 8 & RPN LEVEL IN DESCENDING ORDER
 POTENTIAL FAILURE MODE AND EFECTS ANALYSIS
PART NO : 33 18 202 90 FMEA NUMBER: 940
ITEM : Bearing Bush (PROCESS FMEA) Prepared by : CFT LEADER
Model Year(s)/Vehicles(s) : Key Date : 26.03.2010 FMEA Date (org): 26.03.2010
Core Team : CFT MEMBERS Process Responsibility: CFT LEADER FMEA Date (rev): 10.10.2018 ( K)

Potential Current Current Responsibility Action results

Potential

Occur

RPN
Detec
Class
Sev
Potential Effect(s) Causes Process process Recommended & Target
Process Failure

RPN
of failure Mechanism(s) of Controls controls Action(s) Completion

Occ
Sev

Det
Mode Action taken
failure prevention detection Date

First off
&
INT: Not anwering Wrong selection
4 2 Nil in-process 6 48
into final form core of first form core
inspection.
Closing of
two ends. First off
&
24 INT: Not anwering Improper ram
4 3 Nil in-process 6 72
FIRST into Final form core movement
inspection.
FORMING
( Pre form the
First off
bushes with Open out
INT: Not seating Improper ram &
out Twist and of two 4 2 Nil 6 48
into final form die movement in-process
damages ) ends. inspection.

First off
INT: Clinch mis- &
Stopper not set
Twist match during 5 2 Nil in-process 6 60
correctly
forming inspection.

ABBREVATIONS: INT: INTERNAL, EXT: EXTERNAL ACTION PLAN TO BE CARRIED OUT IF THE SEVERITY > 8 & RPN LEVEL IN DESCENDING ORDER
 POTENTIAL FAILURE MODE AND EFECTS ANALYSIS
PART NO : 33 18 202 90 FMEA NUMBER: 940
ITEM : Bearing Bush (PROCESS FMEA) Prepared by : CFT LEADER
Model Year(s)/Vehicles(s) : Key Date : 26.03.2010 FMEA Date (org): 26.03.2010
Core Team : CFT MEMBERS Process Responsibility: CFT LEADER FMEA Date (rev): 10.10.2018 ( K)
Current Current Responsibility Action results
Potential Potential Causes

RPN
Occur

Detec
Class
Sev
Potential Effect(s) of Process process Recommended & Target
Process Failure Mechanism(s) of

RPN
failure Controls controls Action(s) Completion

Occ
Sev

Det
Mode failure Action taken
prevention detection Date
First off
Outside Maintained
EXT: Difficult to Worn out of &
diameter
housing
6 @ Final form dies
2 tool history
in-process
6 72
oversize card
inspection
First off
Outside
EXT:Less interference Maintain 50% of &
diameter
in housing
8 @ tolerance
1 Nil
in-process
6 48
undersize
inspection
First off
Wall Maintained
EXT: Shaft not Worn out of &
thickness 6 2 tool history 6 72
answering Final form core in-process
oversize card
inspection

26
First off
FINAL Wall Wrong selection
EXT: More play &
FORMING thickness 7 of final form 2 Nil 6 84
between bush & shaft in-process
undersize core
inspection

First off & in-

Jammed on INT: High rejection
6 Improper loading 2 Nil process 6 72
die PPM
inspection.

First off
Worn out of
Less Blue EXT: Less contact in Tool history &
6 Final form core 2 6 72
contanct housing card in-process
& die
inspection
First off
Worn out of
EXT: Difficult to Tool history &
More Ovality 6 Final form core 2 6 72
housing card in-process
& die
inspection
ABBREVATIONS: INT: INTERNAL, EXT: EXTERNAL ACTION PLAN TO BE CARRIED OUT IF THE SEVERITY > 8 & RPN LEVEL IN DESCENDING ORDER
 POTENTIAL FAILURE MODE AND EFECTS ANALYSIS
PART NO : 33 18 202 90 FMEA NUMBER: 940
ITEM : Bearing Bush (PROCESS FMEA) Prepared by : CFT LEADER
Model Year(s)/Vehicles(s) : Key Date : 26.03.2010 FMEA Date (org): 26.03.2010
Core Team : CFT MEMBERS Process Responsibility: CFT LEADER FMEA Date (rev): 10.10.2018 ( K)

Current Current Responsibility Action results

Potential Potential Causes

RPN
Occur

Detec
Class
Sev
Process Function Potential Effect(s) Process process Recommended & Target
Failure Mechanism(s) of
Requirement of failure Controls controls Action(s) Completion

RPN
Occ
Sev

Det
Mode failure Action taken
prevention detection Date

Outside
EXT: Difficult to Wrong 100%
diameter
housing
6 @ inspection
2 -
Inspection
5 60
oversize
90
OD
INSPECTION

Outside EXT:Less
Wrong 100%
diameter interference in 8 @ inspection
2 -
Inspection
5 80
undersize housing

ABBREVATIONS: INT: INTERNAL, EXT: EXTERNAL ACTION PLAN TO BE CARRIED OUT IF THE SEVERITY > 8 & RPN LEVEL IN DESCENDING ORDER
 POTENTIAL FAILURE MODE AND EFECTS ANALYSIS
PART NO : 33 18 202 90 FMEA NUMBER: 940
ITEM : Bearing Bush (PROCESS FMEA) Prepared by : CFT LEADER
Model Year(s)/Vehicles(s) : Key Date : 26.03.2010 FMEA Date (org): 26.03.2010
Core Team : CFT MEMBERS Process Responsibility: CFT LEADER FMEA Date (rev): 10.10.2018 ( K)

Action results
Potential Current Current Responsibility
Process Potential

Occur

RPN
Detec
Class
Sev

Potential Effect(s) Causes Process process Recommended & Target

Function Failure

RPN
of failure Mechanism(s) of Controls controls Action(s) Completion

Occ
Sev

Det
Requirement Mode Action taken
failure prevention detection Date

First off
27
&
STRESS More EXT: Difficult in Temperature and
5 2 Nil in-process 6 60
RELIEVING ovality housing time variation
inspection.
(OPTIONAL)

ABBREVATIONS: INT: INTERNAL, EXT: EXTERNAL ACTION PLAN TO BE CARRIED OUT IF THE SEVERITY > 8 & RPN LEVEL IN DESCENDING ORDER
 POTENTIAL FAILURE MODE AND EFECTS ANALYSIS
PART NO : 33 18 202 90 FMEA NUMBER: 940
ITEM : Bearing Bush (PROCESS FMEA) Prepared by : CFT LEADER
Model Year(s)/Vehicles(s) : Key Date : 26.03.2010 FMEA Date (org): 26.03.2010
Core Team : CFT MEMBERS Process Responsibility: CFT LEADER FMEA Date (rev): 10.10.2018 ( K)

Current Current Responsibility Action results

Process Potential Potential Causes

RPN
Occur

Detec
Class
Sev
Potential Effect(s) Process process Recommended & Target
Function Failure Mechanism(s) of
of failure Controls controls Action(s) Completion

RPN
Occ
Sev

Det
Requirement Mode failure Action taken
prevention detection Date

EXT: Shaft or First off

Chamfer
Bush width housing will Facing tool worn &
6 2 tool life 6 72
Oversize damage out in-process
validated
inspection.
First off
EXT: Gap in
Bush width &
housing causes 4 In correct setting 2 Nil 6 48
Undersize in-process
more end play.
inspection.
First off
OD EXT:1. Difficult &
30 chamfer during assembly Chamfering tool
5 2 Nil in-process 6 60
FACING & length 2. Shearing the worn out
inspection.
CHAMFERING undersize housing
(Maintain the
width and create
OD First off
EXT: Difficult in Chamfering tool
the OD chamfer chamfer &
assembly. 4 not tighten 2 Nil 6 48
and ID chamfer length in-process
properly
of the bushes) oversize inspection.
First off
ID &
EXT:1. Difficult Facing tool worn
chamfer 5 2 Nil in-process 6 60
during assembly out
undersize inspection.

First off
ID EXT: Difficult in
&
chamfer pressing. 4 In correct setting 2 Nil 6 48
in-process
oversize
inspection.
ABBREVATIONS: INT: INTERNAL, EXT: EXTERNAL ACTION PLAN TO BE CARRIED OUT IF THE SEVERITY > 8 & RPN LEVEL IN DESCENDING ORDER
 POTENTIAL FAILURE MODE AND EFECTS ANALYSIS
PART NO : 33 18 202 90 FMEA NUMBER: 940
ITEM : Bearing Bush (PROCESS FMEA) Prepared by : CFT LEADER
Model Year(s)/Vehicles(s) : Key Date : 26.03.2010 FMEA Date (org): 26.03.2010
Core Team : CFT MEMBERS Process Responsibility: CFT LEADER FMEA Date (rev): 10.10.2018 ( K)

Current Current Responsibility Action results

Potential Potential Causes

Occur

RPN
Detec
Class
Sev
Process Function Potential Effect(s) Process process Recommended & Target
Failure Mechanism(s) of
Requirement of failure Controls controls Action(s) Completion

RPN
Occ
Sev

Det
Mode failure Action taken
prevention detection Date

EXT: Poor Hooter Visual

Dull Finish 5 Improper timing 2 8 80
appearance Alarm Inspection

33
TIN FLASH
Excess Current
EXT: Shaft (Disturb between Visual
Roughness 5 2 8 80
Damage Anode & Inspection
cathode)

ABBREVATIONS: INT: INTERNAL, EXT: EXTERNAL ACTION PLAN TO BE CARRIED OUT IF THE SEVERITY > 8 & RPN LEVEL IN DESCENDING ORDER
 POTENTIAL FAILURE MODE AND EFECTS ANALYSIS
PART NO : 33 18 202 90 FMEA NUMBER: 940
ITEM : Bearing Bush (PROCESS FMEA) Prepared by : CFT LEADER
Model Year(s)/Vehicles(s) : Key Date : 26.03.2010 FMEA Date (org): 26.03.2010
Core Team : CFT MEMBERS Process Responsibility: CFT LEADER FMEA Date (rev): 10.10.2018 ( K)

Current Current Responsibility Action results

Process Potential Potential Causes

RPN
Occur

Detec
Class
Sev
Potential Effect(s) Process process Recommended & Target
Function Failure Mechanism(s) of
of failure Controls controls Action(s) Completion

RPN
Occ
Sev

Det
Requirement Mode failure Action taken
prevention detection Date

Inside
First off
diameter
EXT:1.Wall &
undersize / Wear of boring Tool life
oversize cause 6 2 in-process 6 72
Wall tool & insert monitoring
shaft not answering inspection.
thickness
oversize

Inside
36 EXT:1.Wall First off
diameter
ID BORING oversize / undersize cause &
more clearance 5 Improper setting 2 NA in-process 6 60
Wall
between shaft & inspection.
thickness
housing
undersize

First off
&
Rough EXT: Damage on Tool life
5 Boring tool wear 2 in-process 6 50
Finish shaft will occur monitoring
inspection.

ABBREVATIONS: INT: INTERNAL, EXT: EXTERNAL ACTION PLAN TO BE CARRIED OUT IF THE SEVERITY > 8 & RPN LEVEL IN DESCENDING ORDER
 POTENTIAL FAILURE MODE AND EFECTS ANALYSIS
PART NO : 33 18 202 90 FMEA NUMBER: 940
ITEM : Bearing Bush (PROCESS FMEA) Prepared by : CFT LEADER
Model Year(s)/Vehicles(s) : Key Date : 26.03.2010 FMEA Date (org): 26.03.2010
Core Team : CFT MEMBERS Process Responsibility: CFT LEADER FMEA Date (rev): 10.10.2018 ( K)

Current Current Responsibility Action results

Potential Potential Causes

RPN
Occur

Detec
Class
Sev
Process Function Potential Effect(s) Process process Recommended & Target
Failure Mechanism(s) of

RPN
Requirement of failure Controls controls Action(s) Completion

Occ
Sev

Det
Mode failure Action taken
prevention detection Date

EXT: Wrong Mixup of other Final

Mixup bushes received 5 parts during 2 Nil Inspection 6 60
cause line stoppage processing Audit

EXT: Shaft will Visual

99 5 Not oil dipped 2 Nil 8 80
damage or tear Inspection
VISUAL
INSPECTION Rust
& OIL EXT: Visual Rust Preventive
Visual
DIPPING appearance not OK 6 Oil moisture 2 Nil 8 96
Inspection
& housing damage contamination

Improper
Miss out of EXT: Line Visual
6 inspection of 2 Nil 8 96
operation stoppage Inspection
bushes
ABBREVATIONS: INT: INTERNAL, EXT: EXTERNAL ACTION PLAN TO BE CARRIED OUT IF THE SEVERITY > 8 & RPN LEVEL IN DESCENDING ORDER
 POTENTIAL FAILURE MODE AND EFECTS ANALYSIS
PART NO : 33 18 202 90 FMEA NUMBER: 940
ITEM : Bearing Bush (PROCESS FMEA) Prepared by : CFT LEADER
Model Year(s)/Vehicles(s) : Key Date : 26.03.2010 FMEA Date (org): 26.03.2010
Core Team : CFT MEMBERS Process Responsibility: CFT LEADER FMEA Date (rev): 10.10.2018 ( K)

Current Current Responsibility Action results

Potential Potential Causes

RPN
Occur

Detec
Class
Sev
Process Function Potential Effect(s) Process process Recommended & Target
Failure Mechanism(s) of

RPN
Requirement of failure Controls controls Action(s) Completion

Occ
Sev

Det
Mode failure Action taken
prevention detection Date

Outside Final
EXT: Difficult to Wrong
diameter
housing
6 @ Inspection
2 Nil Inspection 7 84
oversize audit

Outside EXT:Less Final

Wrong
diameter interference in 8 @ Inspection
1 Nil Inspection 7 56
undersize housing audit

Wall EXT:1.Wall Final

Wrong
100 thickness oversize cause shaft 6 2 Nil Inspection 7 84
Inspection
FINAL oversize not answering audit
INSPECTION
AUDIT

EXT:1.Wall
Wall undersize cause Final
Wrong
thickness more clearance 7 2 Nil Inspection 7 98
Inspection
undersize between shaft & audit
housing

EXT: Shaft or
Final
Bush length housing will Wrong
6 2 Nil Inspection 7 84
Oversize damage Inspection
audit
 POTENTIAL FAILURE MODE AND EFECTS ANALYSIS
PART NO : 33 18 202 90 FMEA NUMBER: 940
ITEM : Bearing Bush (PROCESS FMEA) Prepared by : CFT LEADER
Model Year(s)/Vehicles(s) : Key Date : 26.03.2010 FMEA Date (org): 26.03.2010
Core Team : CFT MEMBERS Process Responsibility: CFT LEADER FMEA Date (rev): 10.10.2018 ( K)

Current Current Responsibility Action results

Potential Potential Causes

RPN
Occur

Detec
Class
Sev
Process Function Potential Effect(s) Process process Recommended & Target
Failure Mechanism(s) of

RPN
Requirement of failure Controls controls Action(s) Completion

Occ
Sev

Det
Mode failure Action taken
prevention detection Date

EXT: Gap in Final

Bush length Wrong
housing causes 6 2 Nil Inspection 7 84
Undersize Inspection
more end play. audit

Groove EXT:1. Less oil Final

Wrong
location flow leads oil 6 2 Nil Inspection 7 84
Inspection
shift starvation. audit

100 Groove EXT:1. Less oil

Final
FINAL wall flow Wrong
6 2 Nil Inspection 7 60
INSPECTION thickness 2. Shaft will be Inspection
audit
AUDIT oversize wear

Groove EXT:1. Excess oil

Final
wall flow Wrong
6 2 Nil Inspection 7 84
thickness 2. Excess oil flow Inspection
audit
undersize cause oil leakage

EXT: Visual Final

Visual Wrong
appearance not OK 6 2 - Inspection 7 84
defects Inspection
& housing damage audit

ABBREVATIONS: INT: INTERNAL, EXT: EXTERNAL ACTION PLAN TO BE CARRIED OUT IF THE SEVERITY > 8 & RPN LEVEL IN DESCENDING ORDER
 POTENTIAL FAILURE MODE AND EFECTS ANALYSIS
PART NO : 33 18 202 90 FMEA NUMBER: 940
ITEM : Bearing Bush (PROCESS FMEA) Prepared by : CFT LEADER
Model Year(s)/Vehicles(s) : Key Date : 26.03.2010 FMEA Date (org): 26.03.2010
Core Team : CFT MEMBERS Process Responsibility: CFT LEADER FMEA Date (rev): 10.10.2018 ( K)

Current Current Responsibility Action results

Potential Potential Causes

RPN
Occur

Detec
Class
Sev
Process Function Potential Effect(s) Process process Recommended & Target
Failure Mechanism(s) of

RPN
Requirement of failure Controls controls Action(s) Completion

Occ
Sev

Det
Mode failure Action taken
prevention detection Date

EXT: Wrong Final

No proper
Mixup bushes received 5 3 Nil Product 7 105
identification
cause line stoppage Audit

Final
110 Qty EXT: Line
5 Wrong counting 2 Nil Product 7 70
PACKING shortage stoppage
Audit

Final
Packing EXT: Received Improper
6 2 Nil Product 7 84
damage damaged bushes packing
Audit

ABBREVATIONS: INT: INTERNAL, EXT: EXTERNAL ACTION PLAN TO BE CARRIED OUT IF THE SEVERITY > 8 & RPN LEVEL IN DESCENDING ORDER