PT.

VS TECHNOLOGY INDONESIA
POTENTIAL FAILURE MODE AND EFFECTS A
Part Name / Process BASE ROOF CONSOLE Process Responsibility
Injection Molding
Part No 7779-617-A00
Model 578W (1) Prod Trial Target Date 5-Jun-15
Team Members : 1. Sari (ENG) 6. Indra (Maintenance) Pre-Prod Target Date 26-Mar-15
2. Iskandar (QC) Customer Name: PT MINDA ASEAN AUTOMOTIVE
3. Hari (Production)
4. Mr. Wong (Tooling)
5. Nur M. (PPC)

Potential Effects

SEVERITY

OCCUR
Potential Cause / Mechanisms
Process / Station Potential Failure Mode of Failure
of Failure

Can not use, delay in Supplier wrong delivery or

1. Incoming Material Receipt of wrong Resin 6 1
production line loading

Missout COC/DO/MSDS/
2. Incoming Inspection NG Color 8 Not checking material 1
checking and wrong labeling

Difficulity in locating the Different material mixed on

3. Resin Storage Material stored at wrong place material and delay in issuance 6 1
same pallet during storage
to production

Wrong material and wrong

4. Issuance to Production color Production delay 8 Wrong identification 1
 a) Insufficient drying
temperature and time Cosmetic and appearance Dryer malfunction, insufficient
5. Material Preheating b)Excessive moisture level 5 2
issue temperature and time
c) No Heating
d) Over Heating

a) MTC malfunction
a) No heating / Over Heating b) Cosmetic, Appearance, Color b) Chiller malfunction
6. Mold Heating / Cooling Insufficient heating c) 4 4
change and Warpage Issues c) Wrong temperature setting
Insufficient Cooling d) Blockage of cooling channels

7. Special Character Not doing checking

D/1 2 - 62±0.2 Out of Spec 7 2
Checking characteristic dimension

Not doing checking

C/2 83.5 ± 0.2 Out of Spec 7 2
characteristic dimension

Not doing checking

E/4 109.5 ± 0.2 Out of Spec 7 2
characteristic dimension

Not doing checking

H/5 2 - 96.5 ± 0.2 Out of Spec 7 2
characteristic dimension

Not doing checking

CF JIG: GAP & TRIM Out of Spec 7 2
characteristic dimension

Machine setting not maximal,

8. Molding Process 1. Flow Mark Appearance NG 6 2
mold temperature not hot

2. Oily Appearance NG 6 Material / Mold have dirty 2

Mold/tooling have
3. Scractches Appearance NG 6 2
scratch/handling by operator
 Potential Effects

SEVERITY

OCCUR
Potential Cause / Mechanisms
Process / Station Potential Failure Mode of Failure
of Failure

Low Speed / Low Pressure /

8. Molding Process 4. Sink Mark * Appearance NG 6 Low temperature and 2
inadequate airvent

Low Speed / Low Pressure /

5. Short mold Appearance NG 6 Low temperature and 2
inadequate airvent

Barrel temperature high /

6. Silver Streaks * Appearance NG 5 4
Insufficient preheating

Low Speed / Low Pressure /

7. Weld line * Appearance NG 5 Low temperature and 2
inadequate airvent

8. Black Dot * Appearance NG 6 Mixing material 1

Over pack / High Speed /

9. Flashes * Fitting and functional problem 5 2
Temperature High

9. In-Process Inspection Defects and dimension Re-work / repair and can not 5 Lock of knowledge on job 4
(IPQC) overlooked delivery
 Consumable calculation
10. Packing 1. Impra box shortage Packing not standard 4 3
shortage by PPC

Consumable calculation
2. Partition shortage Packing not standard 4 3
shortage by PPC

Operator wrong doing packing

3. Qty part shortage Packing not standard 6 2
qty follow to Std packing

Wrong write down and wrong

4. Wrong Label Mixing part & qty part 6 2
place the box by operator

Non detection of dispancy on Non compliance with Can not recognize the deffect
11. Outgoing Inspection 5 2
quality and quantity of FG customer requirement due to no reference

Difficulity in locating the

Different part numbers, mixed
12. Storage of Finish Good Finished parts at wrong place fiished parts and discripancy 6 1
on same pallet
on inventory. Delay in delivery

13. Delivery Wrong Part No. Delay delivery due to sorting 3 Mistake of pull-out from store 2
MODE AND EFFECTS ANALYSIS ( PROCESS FMEA )
Page No. 1 of 2
ection Molding
Prepared by :
Jun-15
-Mar-15 Approved by
T MINDA ASEAN AUTOMOTIVE ( Supplier )
FMEA No. FMEA/15/03/037
FMEA Date 21-Apr-15
Rev . No 0

Current Process Control Resu

Responsibility &

DETECT

RPN
Recommended Action(s) Target Completion Action taken

SEVERITY
Current Process Controls Current Process Controls Date
Prevention Detection

Visual checking of received

Supplier confirmation on PO Material Store (MS)
material vs 7 42 None
before delivery and IQC
DO/COC/MSDS/Color Chip

Visual checking of received

Every incoming material must Material Store (MS)
material vs 7 56 None
checking by MS & IQC and IQC
DO/COC/MSDS/Color Chip

Using specified area with Use of material directory 7 42 None Material Store (MS)
identification tags

Reference daily production Compare the material

schedule for material specification requisition from with store 7 56 None Material Store (MS)
grade and color issuance slip
Following the material drying SPV Injection &
Daily Machine Inspection List 6 60 None
procedure Maintenance

Follow Daily Maintenance Check 4 hourly Machine Inspection SPV Injection &
4 64 None
List Routine Mold Servicing List Maintenance

Doing checking sample every Doing checking by IPQC 84 Done & Continue
6
setting and per shif Molding monitoring

Doing checking sample every Doing checking by IPQC 6 84 Done & Continue
setting and per shif Molding monitoring

Doing checking sample every Doing checking by IPQC 84 Done & Continue Leader Molding &
6
setting and per shif Molding monitoring IPQC Molding

Doing checking sample every Doing checking by IPQC 84 Done & Continue
6
setting and per shif Molding monitoring

Doing checking sample every Doing checking by IPQC 84 Done & Continue
6
setting and per shif Molding monitoring

Re-setting injection pressure &

Controlling injection pressure 4 48 None
visual checking
Controll mold and material 48 Have Cleaning and
Checking material & Mold 4
before production checking by operator

Re-checking tooling polishing Operator must checking with 48 Check tooling when start
4
periodic & rework methods visual check up & trianing operator
 Page No. 2 of 2

Current Process Control Resu

Responsibility &

DETECT

RPN
Recommended Action(s) Target Completion Action taken

SEVERITY
Current Process Controls Current Process Controls Date
Prevention Detection

Check injection presure

Follow standard MC parameter condition and temperature 4 48 None
setting & Visual checking every day

Check injection presure

Follow standard MC parameter condition and temperature 5 60 None
setting every day

Following the material drying 80 Done & Continue

Daily checking 4
procedure monitoring
Leader Molding &
Checking setting IPQC Molding
Follow MC parameter standard Control injection presure & 4 40 parameter refer to
setting visual checking the output standard
Controlling input material by Checking by leader 4 24 None
leader

make sure checking every

Re-setting injection pressure & 50 parts from MC, controll
Controll injection pressure 5
visual checking setting parameter &
Rework use Noga jig

On job training, work instruction QA Supervisor / Engineering 80 Done & continue SPV QA &
4
and use limit samples review monitoring Engineering
Re-calculation the packing usage Separate the impra box & 48 Re-calculation & additional
4
by PPC calculation when incoming buffer stock

Re-calculation the packing usage Separate the impra box & 48 Re-calculation & additional
4
by PPC calculation when incoming buffer stock Leader PPC, Leader
Operator must follow to std Molding, Leader
Checking the qty packing & follow packing & inform to leader Store
3 36 None
to Std packing before process

Re-checking & place the box refer Have identification label at line
4 48 None
to standard production

Use of Inspection Instruction and Comparison with the standard SPV QA &
4 40 None
Standard Packaging sample Engineering

Visual check of the transfer slip As per Bean system 7 42 None SPV Store
against actual product received

Proper FG labelling as per Visual check of parts against 5 30 None SPV Store
Standard Packaging DO
OCCUR
DETECT

Result
RPN
OCCUR
DETECT

Result
RPN
Opportunity for Detection
No detection opportunity
Not likely to detect at any stage
Problem Detection Post
Processing
Problem Detection at Source
Problem Detection Post
Processing
Opportunity for Detection
Problem Detection at Source
Problem Detection Post
Processing
Problem Detection at Source
Criteria: Likelihood of Detection by Process Control Rank Likelihood of
Detection
No current process control; Cannot detect or is not analyzed. 10 Almost Impossible
Failure Mode and/or Error (Cause) is not easily detected (e.g., random 9 Very Remote
audits).
Failure Mode detection post-processing by operator through 8 Remote
visual/tactile/audible means.
Failure Mode detection in-station by operator through 7 Very Low
visual/tactile/audible means or post-processing through use of
attribute gauging (go/no-go, manual torque check/clicker wrench,
etc.).
Failure Mode detection post-processing by operator through use of 6 Low
variable gauging or in-station by operator through use of attribute
gauging (go/no-go, manual torque check/clicker wrench, etc.).
Criteria: Likelihood of Detection by Process Control Rank Likelihood of
Detection
Failure Mode or Error (Cause) detection in-station by operator 5 Moderate
through use of variable gauging or by automated controls in-station
that will detect discrepant part and notify operator (light, buzzer, etc.).
Gauging performed on set-up and first-piece check (for set-up causes
only).
Failure Mode detection post-processing by automated controls that 4 Moderately High
will detect discrepant part and lock part to prevent further processing.
Failure Mode detection in-station by automated controls that will 3 High
detect discrepant part and automatically lock part in station to prevent
further processing.
Problem Detection at Source
Error Detection and/or Problem
Prevention
Detection not applicable; Error
Prevention
Failure Mode detection in-station by automated controls that will 3 High
detect discrepant part and automatically lock part in station to prevent
further processing.
Error (Cause) detection in-station by automated controls that will 2 Very High
detect error and prevent discrepant part from being made.
Error (Cause) prevention as a result of fixture design, machine design 1 Almost Certain
or part design. Discrepant parts cannot be made because item has been
error-proofed by process/product design.
Suggested PFMEA Occurrence Evaluation Criteria

Rank Likelihood of Failure Criteria: Occurrence of Cause – PFMEA (incidents per items / vehicles)

10 Very High > 1 in 10 ≥ 100 per thousand pieces`

9 High 1 in 20 50 per thousand pieces

8 1 in 50 20 per thousand pieces

7 1 in 100 10 per thousand pieces

6 Moderate 1 in 500 2 per thousand pieces

5 1 in 2,000 0.5 per thousand pieces

4 1 in 10,000 0.1 per thousand pieces

3 Low 1 in 100,000 0.01 per thousand pieces

2 1 in 1,000,000 < 0.001 per thousand pieces

1 Very Low - Failure is eliminated through preventive control

Suggested PFMEA Severity Evaluation Criteria

Effect (Customer Effect) Rank Effect (Manufacturing / Assembly Effect)

Criteria: Severity of Effect on PRODUCT Criteria: Severity of Effect on PROCESS

Failure to Meet Potential failure mode affects safe vehicle operation and/or 10 Failure to Meet May endanger operator (machine or assembly) without
Safety and/or involves noncompliance with government regulation without Safety and/or warning
Regulatory warning Regulatory
Requirements Requirements
Potential failure mode affects safe vehicle operation and/or 9 May endanger operator (machine or assembly) with warning
involves noncompliance with government regulation with
warning

Loss or Loss of primary function (Vehicle inoperable, does not 8 Major 100% of product may have to be scrapped, Line shutdown or
Degradation affect safe vehicle operation). Disruption stop ship.
of Primary
Function Degradation of primary function (Vehicle operable, but at 7 Significant A portion of the production run may have to be scrapped.
reduced level of performance. Disruption Deviation from primary process including decreased line
speed or added manpower.

Loss or Loss of secondary function (Vehicle operable, but Comfort/ 6 Moderate 100% of production run may have to reworked off line and
Degradatio Convenience Inoperable) Disruption accepted
n of
Secondary
Function

Suggested PFMEA Severity Evaluation Criteria

Effect (Customer Effect) Rank Effect (Manufacturing / Assembly Effect)

Criteria: Severity of Effect on PRODUCT Criteria: Severity of Effect on PROCESS
Loss or Degradation of secondary function (Vehicle operable, but 5 Moderate A portion of the production run may have to be reworked off
Degradation of Comfort/ Convenience functions at reduced level of Disruption line and accepted.
Secondary performance)
Function

Annoyance Appearance or Audible Noise, vehicle operable, item does 4 Moderate 100% of production run may have to be reworked in station
not conform and noticed by most customers (< 75%) Disruption before it is processed.
Appearance or Audible Noise, vehicle operable, item does 3 A portion of the production run may have to be reworked in-
not conform and noticed by many customers (< 50%) station before it is processed
Annoyance Moderate
Disruption

Appearance or Audible Noise, vehicle operable, item does 3 A portion of the production run may have to be reworked in-
not conform and noticed by many customers (< 50%) station before it is processed

Appearance or Audible Noise, vehicle operable, item does 2 Minor Slight inconvenience to process, operation, or operator.
not conform and noticed by discriminating customers (< Disruption
25%)
No Effect No discernible effect 1 No effect No discernible effect.
 ly Effect)
t on PROCESS

or assembly) without

or assembly) with warning

scrapped, Line shutdown or

ay have to be scrapped.
ncluding decreased line

e to reworked off line and

bly Effect)
ct on PROCESS
may have to be reworked off

e to be reworked in station

e to be reworked in-
e to be reworked in-

operation, or operator.