POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS IN MANUFACTURING AND ASSEMBLY PROCESSES FMEA Number MM-2000 (PROCESS FMEA)

Item MM-2X Model Year(s)/Program(s) 2001/N/A Core Team Sam and Janet Eveling
Process Function

Process Responsibility Goodson Key Date 4/24/2001

Prepared By R. Yates/867-5309 FMEA Date (Orig.) 2/2/1999 (Rev.) 03/02/2001

Potential Failure Potential Effect(s) of Mode Failure

S e v

Class

Potential Cause(s)/ Mechanism(s) of Failure

O c c

Requirements

Current Process Controls - Prevention - Detection

D e t

R P N

Recommended Action(s)

Resp. & Target Compl. Date

Action Results

Actions Taken

S e v

O c c

D e t

R P N

010 - Wind wire around index finger 001 - Coil diameter

Diameter too large - Coil hits battery during operation - Rotor is short because too much material is used in coils Diameter too small - Weak motor - Difficult removal from finger Diameter too large - Coil hits battery during operation - Rotor is short because too much material is used in coils Diameter too small - Weak motor - Difficult removal from finger

Wire wound loosely

3 >Char Control 1: Measure with gage.

96 None

None

Finger too small

72 None

None

Finger too large

120 None

None

Wire wound tight

002 - # of coils Too few coils

- Motor too weak

Operator miscounts

- Rotor too short to reach supports - Motor too powerful - Wasted material 110 - Coil Starting position - Opposing wire end starting position too incorrect (long too short to reach or short) support - Not enough wire to wind all coils

Too many coils

Not enough wire Operator miscounts

2 >Char Control 1: Operator counts number of coils out loud. 3 2

144 Provide operator with a tool for grasping the wire that limits the tension. 30 None

Tool Engineering 6/6/1999

Tool developed, tested, and implemented at process step 010. None

54

4 3

60 None 48 None

None None

Light dim so ruler hard to read

2 >Char Control 1: Use ruler to locate start position.

42 None

None

Ruler worn so hard to read

63 None

None

4/5/2001 12:21:30 PM

PFMEA MM-2000

This is not a controlled document

Page 1 of 2

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS IN MANUFACTURING AND ASSEMBLY PROCESSES FMEA Number MM-2000 (PROCESS FMEA)
Item MM-2X Model Year(s)/Program(s) 2001/N/A Core Team Sam and Janet Eveling
Process Function

Process Responsibility Goodson Key Date 4/24/2001

Prepared By R. Yates/867-5309 FMEA Date (Orig.) 2/2/1999 (Rev.) 03/02/2001

Potential Failure Potential Effect(s) of Mode Failure

S e v

Class

Potential Cause(s)/ Mechanism(s) of Failure

O c c

Requirements

Current Process Controls - Prevention - Detection

D e t

R P N

Recommended Action(s)

Resp. & Target Compl. Date

Action Results

Actions Taken

S e v

O c c

D e t

R P N

020 - Slip wound wire off finger 111 - Maintain Rotor mis-shapen rotor shape 030 - Sand coating off wire ends 004 - Length of Bare wire too long coating removed Bar wire too short 113 - Sanding Sanding time too time long Sanding time too short 040 - Store finished wire (rotor) 100 - Maintain Lot ID lost lot ID 111 - Maintain Rotor mis-shapen rotor shape 050 - Bend clips to make supports 005 - Rotor Support missupport shaped shapen like print 060 - Store rotor supports 100 - Maintain Lot ID lost lot ID 112 - Maintain Support missupport shape shapen

None

None

0 0 0 0

None None None None

None None None None

0 0

None None

None None

None

None

0 0

None None

None None

4/5/2001 12:21:31 PM

PFMEA MM-2000

This is not a controlled document

Page 2 of 2