Process FailureMode and EffectsAnalysis (ProcessFMEA)SCOPE DEFINITION (Step 1)Name of company responsibleSystem/sub-Company Name:for PFMEASubject:Name of PFMEA projectsystem/component/Name of system elementDetermined by themissed contextsin draft Plant Location:Geographical locationPFMEA Start Date:Date PFMEA project startedPFMEA ID Number:companyName of customer (s) or [handbookCustomer Name:product family ]PFMEA Revision Date:Date of most recent changeProcess Responsibility:Name of PFMEA owner[ Business Use,Customer application orConfidential,Model Year / Platform:company model / styleCross-Functional Team:Team Roster neededConfidentiality Level:Propriotary, etc. ]STRUCTURE ANALYSIS (Step 2)FUNCTION ANALYSIS (Step 3)FAILURE ANALYSIS (Step 4)RISK ANALYSIS (Step 6)OPTIMIZATION (Step 6)1.2.3.1.2.3.1.E2.3.Current PreventionCurrent DectectionResponsibleTargetStatus:Action TakenCompletionProcess ItemFunction of the Process StepFunction of the Process WorkFailure Effects (FE)FPrevention ActionDetection ActionProcess StepProcess Work ElementFunction of the Process Item Failure Mode (FM) of theFailure Cause (FC) of the WorkControl (PC) of FCControls (DC) of FC orM)fF)rlPersonCompletionwith PointerDate)and Product CharacteristicElement and ProcessoProcess ElementElementCFM/Paa)CAhnDate (TCD)Open,to EvidencePFA )(System, Subsystem, PartStation No. and Name of Focus[ Man, Machine, Material[ In-plant, Ship to plant,Characteristic[In-plant, ship to plant,SfF(Co( iyfyttCompleted,Dis)O) oS(D(yElement or Name of ProcessElement(Indirect), MilieuProcess Item, Vehicle End( Quantitative value isprocess item, vehicle endt)otcpi iuocarded( tO e i(Environment), etc. ]user, when known ]r()rd(ynRemarksoptional )user, when know]creeDoo tnoovc(ireieiiennrPdrrtrSeoP oercP ri lCvue lrtna ectnaucoirSceDonceiceOiicttettgOecplciDASiArFOThe name of the process beingThe operation or station to beUse the 4M's to identity typesA description of what theA description of what theA positive description of howHow the Vehicle, System or1~10Failure mode must beThe Failure Cause is theInitial State - Past1~10Initial State - Past1~10H, M,LLAdditional ActionsAdditional ActionsName, notmm yy or ddOptional:Descriptionmm yy or dd1~101~101~10H, M,For PFMEA teamanalyzed e.g. electrical motoranalyzed that produces theof variation that have anProcess Item is expected tooperation or station mustthe work is completedSubsystem could fail todetectable in the productnegative of the positivecontrols proven and /controls proven and /L, NAneeded to reduceneeded to improvetitle ormm yyof actionmm yyL, NAuseassembly line which is the endProcess Item e.g. OP30influence on the operation orachieve broken down intoachieve e.g. Axial positionincluding the positive processperform the Function described(defect)listed in “Function of theor controls committedor controls committedOccurrenceDetectiondepartmentDecisiontaken andresult of all successfullySintered bearing Press-instation being analyzedseveral categoriessintered bearing in polecharacteristic related to eachat the Next Higher levelProcess Work Element andtotopending,documentcompleted process stepsprocesshousing4MThe Failure Mode will be theProcess Characteristic”Implementationumber,4M Types:Some categories maybe unknownWhen considering Effects,negative or negatives of then pendingreport namemay also be a non-directMan, Machine, Materialand listed as Not ApplicableThis is the positive ProductThe negative of theseconsider items listed in “positive ProductCause must be detectable inand date,manufacturing process e.g.(indirect), Milieu(NA)Characteristic and must bepositives will be used for theFunction of the Process Item”Characteristic.the process (error) and leadetc.shipping(Environment)detectable in the productFailure Cause column The moreand the \to the Failure ModeThese expectations can bedetail used here will producehow they can Effect the 3Considering each side of theList a single \referred to when completingThe Failure Mode or Failuremore Failure Cause i.e. eachareas being considered (In-specification of ProductNew Failure Causes - Whileline.Failure Effects (FE)Modes will be the negative orline is a unique positivePlant, Ship to plant. ProcessCharacteristic ifconsidering “Failure Causesnegatives of the positiveproducing a unique negative,Item, Vehicle End User)specification of Product”, new 'Function of theTypes may vary by companyThese expected results mayProduct Characteristic.i.e. a Failure CauseCharacteristic has a range,Process Work Element andapply for the entire ProcessInclude potential effects tolist Failure Mode for eachProcess Characteristic”, “Item e.g. electrical motorThe Product Characteristic canInstead of “Get correctthe vehicle (End User) levelside of the specification,Product Characteristic andassembly linebe written stating the entiresintered bearing from partend regulations. as applicablei.e., “Torque Bolt to spec”,maybe generated, i.e. listing.positive Productrack and place into fixture”the Failure Modes will be ““Scratched top surface whileIn-plant：Avoid rework andCharacteristic, e g within gapUse “Get correct sinteredIt is recommended to list theTorque loss then spec”, “picking part from rack” canscraptolerance, or using separatebearing” and “Fully placeSeverity Rank next to each ofTorque more than spec” Eachgenerate “Pick part from partShip to plant Installation oflines, considering over andbearing into fixture”Thisthe 3 areas being consideredmay have a different Severityrack without scratching thewindow lifter electrical motorunder tolerance, e g , notidentifies of two separateand use the highest Rank forRank.top surface”, may generateto vehicle doorgreater then max tolerance,Failure Causes, i.e.. “wrongthe Severity Rank. One area,and a new “ProductProcess Item.：Shaft installednot less than min tolerance.part picked” “Bearing notsuch as End User. may notConsidering magnitude of outCharacteristics”, “Topinto pole house assemblyIt may also consider magnitudefully set into fixture” Thealways have the highestof specification If thesurface scratch tree” and aVehicle.：Window raises andof out to tolerance if itmore detail used, the moreSeverity Rankmagnitude of out ofnew Failure Mode “Top surfacelowerseffects the Failure EffectsCauses can be captured in thespecification can affect thescratched”e.g. gap not greater then maxdocumented for risk analysis.Severity Rank. It should heElectrical Motor[OP 30] Sintered bearing pressOperatorProcess Item: Converttolerance by 0~3mm or gap notPress in sintered bearing toOperator takes clean sinteredProcess Item: Loss of8listed, i.e., “No stampingAxial position of sinteredFailure Analysis can beginOperator inserts a sinteredNo Prevention control10Lot release Protect2HCCThe definition of aJohn DoeDD.MM.YYYYIn-progress832Lelectrical energy intoachieve axial position in polebearing from chute and push itmechanical energy because ofbearing is not reached, gapbearing which was dropped toobjectivework instruction(Productionmechanical energy (acc.housing to max gap per printonto the press-in shaft untiltoo much friction betweentoo smallthe ground floor before(effectiveity 100%)and a workEngineer)control signal)the upper stopbearing and shaft, inner(contaminated with dirt)Visual Gaugeinstruction fordiameter of the bearinginspection of axial\In Plant: Assembly ofdeformed because off too muchgap of bearing to polecomponents\components within cycle time,seating stresshousing eat bycontents of thewithout scrap or reworkoperator (check theregularIn Plant: Nonechecker:N/A)Ship to Plant: Assembly ofDectection indicator:Training curricularmotor to vehicle door withoutShip to Plant NoneOK/NOK (RED/GREENthe operator andline stoppage, sort orarea) and operatorfinishing staffcontainmentEnd User: Window raises andseparate the NOK partlowers with difficultyEnd User Window raises andElectrical Motor[OP 30] Sintered bearing pressMachine (press machine)lowersProcess Item: ConvertPress in sintered bearing toMachine has to press in theProcess Item: Loss of8Axial position of sinteredMachine stops before reachingSelected press with3Lot release Protect2M3electrical energy intoachieve axial position in polesintered bearing into the polemechanical energy because ofbearing is not reached, gapfinal position (too lessforce monitoring andobjectivemechanical energy (acc.housing to max gap per printhousing seat until the definedtoo much friction betweentoo smallforce)position control(effectiveity 100%)control signal)axial positionbearing and shaft, innersensorVisual Gaugediameter of the bearinginspection of axialIn Plant: Assembly ofdeformed because off too muchgap of bearing to polecomponents within cycle time,seating stresshousing eat bywithout scrap or reworkoperator (check theIn Plant: Nonechecker:N/A)Ship to Plant: Assembly ofmotor to vehicle door withoutShip to Plant Noneline stoppage, sort orcontainmentEnd User: Window raises andlowers with difficultyElectrical Motor[OP 30] Sintered bearing pressMachine (press machine)End User Window raises andProcess Item: ConvertPress in sintered bearing toMachine has to press in theProcess Item: None7axial position of sinteredMachine stops before reachingSelected press with3Lot release Protect3M3electrical energy intoachieve axial position in polesintered bearing into the polebearing is not reached, gapfinal position (too lessforce monitoring andobjectivemechanical energy (acc.housing to max gap per printhousing seat until the definedIn Plant: Assembly of shaft istoo largeforce)position control(effectiveity 100%)control signal)axial positionnot possible because clearancesensorVisual Gaugetoo small (scrap 7),inspection of axialIn Plant: Assembly ofexcessive line cycle time (7)gap of bearing to polecomponents within cycle time,housing eat bywithout scrap or reworkShip to Plant: n/aoperator (check thechecker:N/A)Ship to Plant: Assembly ofEnd User: n/aDectection indicator:motor to vehicle door withoutOK/NOK (RED/GREENline stoppage, sort orarea) and operatorcontainmentseparate the NOK partEnd User. Window raises andlowersCONTINUOUSIMPROVEMENTHistory / ChangeAuthorization(As Applicable)Examples:A design change:DCN0983885A managementreview:MR07-NOV-2017A customerreview:CR02-FEB-2018
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