Process FMEA

Product:

Example product

Prepared by:

Gavin Robbins

Core
team:

Anon Team

Key Date:

Milestone 1

Process
Step

Case
Moulding

Function

Failure Mode

Produce a Deformation
moulded
of the case
case as per
drawing

Failure Effect

High Scrap

Problems with
assembly to
customers
vehicle

Preventive Action Detection Action

RPN

Project Manager

Detection

Responsibility:

Occurrence

ECU

Severity

Process:

Total Preventative
Maintenance

16

Damaged tool

First off
inspection
Total Preventative
Maintenance
Operator visual
inspection

48

Granulate
moisture content
is out of tolerance

Controlled
environment
within the Silo

First off
inspection

16

Incorrect type of
tool

Work Instructions

First off
inspection

16

Initial setup by
Manufacturing
Engineer

First off
inspection

16

Work Instructions

Operator visual
inspection

Potential Failure
Cause

Thermo-couples
fail
4

Incorrect
temperature
settings

First off
inspection

Incorrect pressure
settings

Incorrect cycle
time
Warranty returns

Rework

6
Incorrect type of
granulate

Flashing
present

Initial setup by
Manufacturing
Engineer

First off
inspection

Work Instructions

Operator visual
inspection

Initial setup by
Manufacturing
Engineer

First off
inspection

Work Instructions

Operator visual
inspection

Incoming
Inspection

NONE

16

16

10

80

48

16

48

Work Instructions

Worn tool

Insufficient
cooling time

Worn tool

First off
inspection
Total Preventative
Maintenance
Operator visual
inspection
First off
Work Instructions
inspection
First off
inspection
Total Preventative
Maintenance
Operator visual
inspection

Page:

Number:
Created:

01/01/2008

RPN

Detection

Actions
Taken

Occurrence

Recommended Responsible &

Actions
Deadline

Severity

Modified: 03/03/2008