f169 Dfmea Front Strip System 01feb2001

Design Failure Mode and Effects Analysis (DFMEA) Instructions
NOTE: Design FMEAs must be prepared for all programs (components, subassemblies and assemblies) where Johnson Controls has full program design responsibility. In cases where the OEM Customer has design responsibility, every effort must be made to document special and safety critical special characteristics for inclusion in the Design FMEA and Control Plan. (A matrix for this purpose and the FMEA Form can be found in the AIAG APQP and Control Plan manual).
1.
INSTRUCTIONS: The System FMEA and/or Design FMEA are to be prepared using the DaimlerChrysler, Ford, and General Motors Potential Failure Mode and Effects Analysis (FMEA) reference manual. Historical campaign, warranty data, high mileage data and P-Diagram noise factors must be reviewed and included in the DFMEA as applicable. Similar part/program DFMEA's must be considered when preparing a DFMEA for all new programs.
2.
3.
4.
The SFMEA and/or DFMEA must identify and address all Special Characteristics (both significant and critical). Design characteristics that affect high risk priority failure modes must be identified.
5.
6.
Appropriate corrective actions must be assigned to high risk priority numbers (RPN 70 and greater).
7.
Appropriate corrective actions must be planned and/or taken for high severity numbers (severity of 7 and greater). Risk priorities must be revised when corrective actions have been completed and verified.
8.
9.
Customer system design specifications numbers must be indicated for each failure mode. (i.e. Ford SDS v4.0, ST-0018 and GM SOR-SSTS xxx)
10. DFMEAs must address all failure modes in areas of Safety, Function, Service, Appearance, BSR, Assembly, Packaging and Comfort.
WW-PLUS-FR-04-31-E / Rev 01
Page 1 of 29
POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (DESIGN FMEA) Customer Design Spec. TJC F169 02 Rev : B Design Responsibility: Prepared by: Date (Orig.) Date (Rev.) XXXXXXXXXX 21.07.2000 23.11.2000 Item: FIAT169 - FRONT SEAT - STRIP VER COMPLETE SYSTEM Customer/Model Year/Platform/Product: FIAT/ 2002/ Team: MG / TKK / VD / SP / MP / SAI / AG / RAO
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Item #
Item Function/ Requirements
Potential Failure Mode
Potential Effect(s) of Failure
S e v
C l a s s
Potential Cause(s)/ Mechanism(s) of Failure
O c c u r
Current Design Controls
D e R. t P. e N. c
Recommended Actions
Responsibility & Target Date
Action Results Actions S O D R. Taken e c e P. v c t N.
Assy Front seat 238442, 238443 1 Safety/ Seat System to provide flush fitting components/mi n. clearance to components with relative motion Seat System does not provide flush fitting components/min. clearance to components with relative motion Occupants finger 5 becomes trapped. SC Incorrect gap size 3 specified on valance/recliner covers Seat side valance/recliner cover to cushion gap to be less than 5 mm or greater than 20 mm. 2 30 0
Incorrect gap size specified on flip up cushion system
Flip up cushion 2 mechanism to occupant handle location to be less than 5 mm or greater than 20 mm. During arc of 3 movement lever grip area not to be within 30 mm of side valance/door bin Recliner handwheel to 2 recliner cover to be less than 5 mm or greater than 20 mm. Layout study. Prototype 2 evaluation
30
4 way lifter handle grip 3 area to side valance gap size incorrectly specified Recliner handwheel grip area to recliner cover gap size incorrectly specified Incorrect gap sizes specified within seat system 2
45
20
Occupants 5 belongings fall into seat system
30
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Item #
S e v
5
C l a s s
O c c u r
D e R. t P. e N. c
30
Recommended Actions

0
Ornamentation permits 3 objects to be funnelled into seat system
Occupant clothing 5 catches/snags 5
Release handle system 3 protrudes into ingress/egress zone 4 way lifter handle protrudes into ingress/egress zone Belt buckle clearance to console. 4
Top edge of valance to 2 flow under seat cushion. 4 way lifter handle to side valance to interlock. Max gap between adjacent components 2 mm Rear of cushion to recliner cover/valance to be flush fitting Towel bar sytem with 2 continuous bar from I/b to o/b slide system Prototype evaluation 4
30
80
Fiat styling and package groups to agree on form and location.
Limited access to belt buckle. Foul condition to adjacent components.
Layout study. Prototype 3 evaluation
45
Pretensioner tube and 2 bracket clearance to console. CC Incorrect design. 1
Layout study. Prototype 3 evaluation Min bend radii 5 mm. 1 No forward facing structure free edges. Cover Track edges in occupant reach by safe edge/de-burred Safe edge around front of pan, covered by trim/plastic. ECE R 17.
30
2 Safety/Seat system not to affect other systems/compo nents/occupant with sharp edges
Seat system does Occupant injury. affect other systems/components/o ccupant with sharp edges
Make min radii greater than min legal by an amount than that of the tolerance band x safety factor
Page 3 of 29
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Item #
S e v
9
C l a s s
O c c u r

Dia 10 mm min tube. Layout study and prototype evaluation Radii Min 2 mm. Smooth profile Plastic grip area with no tool parting lines in grip area Santoprene outer grip area Plastic housing - Min rad 0.5 mm. Full rad around perimeter (Styling approval required from Fiat) No tooling split lines on A surface or self presenting to fitted to Protection cap all front seat back frames. This fixture was POKE YOKE in all JIT plants.
D e R. t P. e N. c
1 9
Recommended Actions
SC Towel bar track release 1 sytem grip area SC 4 way lifter lever grip area 2
36
SC Recliner handwheel grip area
36
SC Valance/recliner cover 2 edge
36
Seat belt damage. 9
YC Incorrect desiign of 1 upper cross member may make sharp edges possible. YC Forward facing edges YC Incorrect material specification. 1 2
9 3 Safety/Seat system to provide a fire resistant system. Seat system does not Occupant injury. provide a fire resistant system. 9
Layout study. Prototype 1 evaluation Material specifications. 2 FMVSS 302.
9 36 0
Page 4 of 29
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Item #

Occupant injury.
S e v
9
C l a s s
O c c u r
2
D e R. t P. e N. c
36
Recommended Actions

0
Seat system does not 4 Safety/Seat provide an electrically system to safe system provide an electrically safe system
YC Incorrect specification ofelectrical components.
YC Incorrect cable routing 1
Legal legislation. 2 Electrical system specification. Controlled by supplier TRW according to Fiat specifications. Route cables to protect 3 from side impact. Fiat approval required. Locate away from 2 water ingress zone. If in zones use sealed type connector systems Connector to connector 2 latching strength - 100 N min. Free cable length for height adjust and flip up cushion systems. Mount connectors on seat with fore/aft Notch depth 2.0 mm 2 Button diameter 0.8 mm ECE R 25.04 ECE R 17.07 Layout study, Prototype 2 evaluation, Customer sign off. Material specifications 2 based on FEA, Surrogate parts
27
YC Water ingress into connector system
36
Electrical system failiure.
Loss of electrical signal 3
36
5 Safety/Seat system to provide an ocupant with a protected environment.
System does not provide a protected environment for the occupant.
Occupant injury.
YC Headrestraint becomes 3 detached from seat structure
54
YC Incorrect Packaging.
36
10 YC Incorrect material selection
40
Page 5 of 29
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Item #

Customer dissatisfaction.
S e v
7
C l a s s
O c c u r
2

Kinematic studies in CAD, Functional seat build
D e R. t P. e N. c
3 42
Recommended Actions

0
System does not 6 Safety/Seat provide correct layout system to provide correct clearances. package clearances.
YS Seat movemnts incomplete due to interference within structure
7 Safety/Seat system to provide adequate strength under static and/or dynamic loadings
Seat system does not provide adequate strength under static and/or dynamic loadings
Occupant injury.
YS Seat movemnts 3 incomplete due to interference with other systems 10 YC New seat structure 2 design/Incorrect design.
Kinematic studies in CAD, Prototype evaluation in vehicle
42
ECE R 14.05,ECE R 3 16.04,ECE 17.07,ECE R 21.01,ECE R 25.04,ECE R 94.01,ECE R 95.01 Engineering issues list. Customer sign off. Homologation. Surrogate structure Front X tube interlock load path with pan ECE 17 ECE 14, Surrogate mechanism 2
60
10 YC Flipup cushion self activates
40
8 Safety/Seat user adjust components to provide adequate strength under static and/or dynamic loadings
Seat user adjust components do not provide adequate strength under static and/or dynamic loadings
Loss of 8 adjustment/feature function
YS Incorrect specification on material section
FEA 2 Free body diagrams Surrogate mechanisms
32
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Item #
S e v
8
C l a s s
O c c u r
2
D e R. t P. e N. c
32
Recommended Actions
YS Incorrect material specification. YS Incorrect use abuse loadings specified
9 General/Seat system to resist excessive freeplay
Seat system does not resist excessive freeplay
Customer experiences some disatisfaction
Front seat back fore/aft 2 movement - recliner heart
FEA 2 Free body diagrams Surrogate mechanisms For finger use levers - 2 150 N For hand use levers - 250 N Surrogate mechanisms T2000 heart. 4 fixngs 2 of recliner to track system - 5 dr. Latch type claw Surrogate mechanism Reduce freeplay at 2 eack pivot location. Rear lift system with frre pivot at front. Single likage system to reduce interfaces. Tolerance study. Surrogate mechanism Dead pan design 2 90 mm Foam depth under H point at centre line. Engineering issues list. Customer sign off. JCI knee test simulate user kneeing on cushion facing rear of seat. Pressure mapping.
32
20
4 way linkage mechanism
30
10 Comfort/Seat system to provide adequate suspension and support.
System does not Customer provide adequate dissatisfaction. supension and support.
YS Loss of cushion support
28
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Item #
S e v
7
C l a s s
O c c u r
3
D e R. t P. e N. c
42
Recommended Actions

0
YS Incorrect package.
Layout study. 2 Customer sign off. Packaging issues list. Pressure mapping. Rear occupant foot zone profile - 25 mm clearance to underside of pan. Clip suspension mat direct to frame 2
Occupant discomfort
YS Loss of FSB suspension mat support YS Incorrect A surface design.
42
JCI design guidelines. 2 Engineering issues list. Customer sign off. JCI knee test 2 simulate user kneeing on cushion facing rear of seat. H pt on complete seat dwg. Foam hardness, 2 density and weight to be monitored. Link with H-point checks Customer sign off on 2 ergonomic curves. Pressure mapping.
24
YS Loss of specified H 3 point, back angle, thigh angle, heel point.
36
YS Incorrect foam hardness specified
36
11 Comfort/Seat system provides an optimum pressure distribution and support.
System does not provide optimum pressure distribution and support.
Customer 5 experiences some disatisfaction
Incorrect A surface design
30
Page 8 of 29
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Item #
S e v
5
C l a s s

Incorrect Foam specification
O c c u r
3
D e R. t P. e N. c
30
Recommended Actions

0
JCI design guidelines. 2 Engineering issues list. Customer sign off. Pressure mapping. Pan B surface to be 90 2 mm from A surface under H point at seat centre line Prressure map test Meat to metal clearance to be min 30 mm Seat slide travel 150 2 mm forward, 60 mm rearward. Height adjust range +/20 mm rear lift Back angle design position 25 deg, rearward from vertical, +/- 15 deg min for comfort (larger angle posible for additional package requirements) Track angle 2 deg Height adjust lever swing +/- 20 deg from start position Towel bar swing 10 deg from start position System design specification. Engineering issues list. Customer sign off.
Incorrect location of B surface on FSC and FSB
30
12 Comfort/seat system provides adequate movement and adjustment.
System does not provide adequate movement and adjustment.
Customer 5 experiences some dissatisfaction.
Incorrect package specification.
30
Page 9 of 29
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Item #

System does not provide sufficient vertical travel.
S e v
C l a s s

Incorrect design.
O c c u r
3
D e R. t P. e N. c
30
Recommended Actions

0
13 Comfort/Syste m to provide sufficient vertical travel
Customert 5 experiences some dissatisfaction. System ergonomically unsuitable for occupant. Occupant discomfort 5
Engineering issues list. 2 Customer sign off.
Incorrect design.
JCI design guidelines. 2 Engineering issues list. Customer sign off.
30
YS Incorrect design.
14 Comfort/Syste m to provide sufficient recline adjustment.
System does not provide sufficient recline adjustment.
Occupant discomfort
YS Incorrect location of end stops
JCI design guidelines. 2 Engineering issues list. Customer sign off. Design position 25 deg 2 rearward of vertical. Min comfort adjustment range +/-15 deg about design position. Package review Additional package adjustment for horizontal rearward condition. (Seat fore aft position can be forward of design in vehicle to prevent clash with rear seat cushion) Soft to soft interfance 3 with structure having min40 mm clearance between sweep paths. (Trim bulging appearance affected. Degree determined by biteline overlap)
36
0 0
36
YS Lower edge of front seat back interfeance with rear of cushion when reclined rearward. (Condition worst when cushion is raised to highest vertical position)
72
Page 10 of 29
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Item #

System does not provide sufficient headrest adjustment.

Occupant discomfort
S e v
6
C l a s s
O c c u r

Package review
D e R. t P. e N. c
2 36
Recommended Actions

0
15 Comfort/Syste m to provide sufficient headrest adjustment.
YS Incorrect noth location 3 specified
Does not meet legal height 16 Comfort/Seat to Seat does not provide adequate ingress provide egress clearance. adequate ingress egress clearance.
YC Incorrect package location Track infringment into rear footwell
3 3
ECE 17 Reduced length outboard lower track section Customer sign off. Packaging issues list. Package checks.
2 3
54 45
Recliner cover/valance 3 infringement into occupant path
Tailor plastic covers 3 close to structure. Min. structure to be determined. Customer sign off. Packaging issues list. Package checks. Fiat approved packaging details 2
45
17 Comfort/Seat system to provide good ergonomic position
Seat system does not provide good ergonomic poition.
Incorrect H point, heel point, back angle specifed
30
Towel bar release system incorrectly positioned
Min 20 mm clearance 3 under lever to vehicle carpet over front cross member. Jury evaluation for reach
45
Page 11 of 29
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Item #
S e v
5
C l a s s

4 way lifter handle incorrectly positioned
O c c u r
3

Jury evaluation for reach Fiat package and styling review Presssure map A surface profiles generated from surrogate and benchmark data
D e R. t P. e N. c
3 45
Recommended Actions

0
18 Comfort/Seat system to provide optimum pressures distribution for long term comfort.
Seat system does not provide optimum pressures distribution for long term comfort.
Incorrect A surface profile
30
Uncorrect B surface location of Pan and FSB suspension mat Incorrect foam specification
FSC - 90 mm foam 2 depth under H point at centre line of seat Pressure map test Pressure map test Component FMEA control of foam hardness, density and weight. Pressure map test Combine with baggy seat test evaluation. Min 30 mm Package sections Pressure map test 2
30
30
Incorrect trim tension
30
Incorrect meat to metal 3 clearances Incorrect seat system adjustment 2
30
Fiat agreed adjustment 2 ranges. Forward - 150 mm Rearward - 60 mm Vertical - +/- 20 mm Recline - min +/- 15 deg
20
Page 12 of 29
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Item #
S e v
C l a s s

Foam collapse
O c c u r
2

Component FMEA to identify controls. ST-0036 followed by pressure map and Durability test Durability test Dead pan FSC Min 30 mm meat to metal
D e R. t P. e N. c
4 40
Recommended Actions
Seat system does not 19 Comfort/Seat provide lifetime system to provide lifetime comfort. comfort.
Customer 5 experiences some disatisfaction
20 Comfort/Seat system to provide adequate meat to metal clearance 21 Appearance/Se at system to provide no or consistant gaps at component/sub system interfaces
Loss of primary function of FSC Seat system does not Occupant provide adequate meat dissatisfaction. to metal clearance
8 6
YS Suspension system collapse Incorrect location of structure
3 3
2 2
48 36
0 0
Seat system does not Defect noticed by provide no or most customers consistant gaps at component/sub system interfaces
Incorrect profiles specified
Customer sign-off Eval 1 - exercise to involve measuring consistency of gaps.
80
Incorrect mating of components/sub systems
Interlock edges of ornamentation Customer sign-off
80
Incorrect profile of FSB 5 top surface and underside of headrest asy 4 way lifter handle 5 profile mis-match with valance
Angle top of FSB to car 4 line
80
Fiat styling review
80
Page 13 of 29
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Item #

Occupant some dissatisfaction.
S e v
5
C l a s s
O c c u r

Lower J retainer to run full length of FSB Customer sign off.
D e R. t P. e N. c
4 100
Recommended Actions

0
22 Appearance/Se Seat system does not conceal internal at system to materials. conceal internal materials.
Visible foam at base of 5 FSB - recliner region
Visible recliner structure when FSB reclined away from design positionvisible Seat structure
Recliner cover to feature return edges. Customer sign off.
80
3 when flip up cushion is in up position - in order to access stowage compartment Cabling system visible 3 in car line
Stowage box to cover 3 slide mechanism Paint cross tubes
45
Clip in trim cover system. Stowage box to produce false profile. Check for cable visibility during flip up operation. Check for cable visibility with seat mounted in vehicl in full package range.
Dedicated fixed cable 2 routing
30
Ornamentation disengages from seat system occupant
Pull out forces to be specified to all ornamentation
45
Page 14 of 29
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Item #

Occupant some dissatisfaction.
S e v
5
C l a s s

Incorrect A surface styling.
O c c u r
5
D e R. t P. e N. c
Recommended Actions

0
23 Apearance/Seat Seat system does not provide wrinkle free system to provide wrinkle trim condition. free trim condition.
Smooth transition 4 between contours. Back up trim with foam and structure as necessary. Rear of front seat cushion on top face of bolster to have positive crowning from front to rear. Joggle depression to be minimised. Development loop together with Foam overbuild. Fiat spec for fabric. Build trials Tolerance study. FSB - align headrest holes with foam and structure. Alignment markers on horizontal tie down. Hog ring centre position first. 4
100 Design guidelines needed for foam / trim profiles to eliminate wrinkle enducing areas.
Incorrect trim pattern profile.
100
5 5 5
Incorrect material 5 selection Sew margins not 5 cosidered for seat style. No alignment aids for 5 trim cover assembly to structure
3 3 4
75 75 100 FSC - centre seam with depression marker at front and rear edge of cushion pan. FSC trim - notches in sew tag to define centreline front & rear alignment features. Investigate solid attachments of lower J strip on FSB to backframe
0 0 0
Page 15 of 29
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Item #
S e v
5
C l a s s

Unsupported trim
O c c u r
5
D e R. t P. e N. c
100
Recommended Actions

0
FSB - lower J to run full 4 length across seat. Back up trim with sufficient foam (overbuild as necessary) and structure. JCI ingress-egress test 4
24 Appearance/Se at system to provide ingress/egress durability 25 Appearance/Se at system to provide a tight fitting cover prior to use.
Seat system does not Fabric wear provide ingress/egress through - defect durability noticed by most customers Seat system does not provide a tight fitting cover prior to use.
Incorrect 3 material/pattern/foam/s eam specification
48
Fabric bridging 3 foam - defect noticed by average customers
Concave foam profile
5mm crowning on 4 surfaces within contact with occupant Blunt hog ring to prevent variability in trim tension during assembly process 4 2
36
3 26 Appearance/Se Seat system does not provide a tight fitting at system to provide a tight cover after use. fitting cover after use. Defect noticed by most customers 5
3 Prototype builds and evaluation Baggy/saggy trim cover 5 Durability tests Excess material
36 50
Baggy map pocket
Plastic strip along top 3 edge sewn into cover. Trim retention along complete lower egde of FSB
48
Page 16 of 29
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Item #
S e v
C l a s s
O c c u r
D e R. t P. e N. c
54
Recommended Actions

0
27 Appearance/Se Seat system does not prevent visible thread at system to prevent visible ends thread ends 28 Apearance/Seat Seat system does not prevent read through system to on A surface prevent read through on A surface
Defect noticed by 3 average customers
Incorrect seam design 3
Control plan for sewing 6
Defect noticed by most customers
Incorrect material selection.
4 4
Incorrect foam profiles 3 Foam tail on fsb wraps 4 around lower cross member of FSB structure. Produces sharp edge over which fabric runs. Split seams during 3 assembly
Min. 4 mm laminate 4 fabric High loft or scrim backed vinyl not to be used over foam tool split lines/channels Styling sign off from 4 Fiat Top rear tie down only. 3 Lower J at lowest point on FSB Prototype builds
48
48 48
19 Appearance/Se Seat system does not Customer provide acceptable trim dissatisfaction. at system to seam appearance provide acceptable trim seam appearance
Prototype builds
48
4 Seat system does not 30 Apearance /Seat system to provide design intent provide design colours. intent colours. Customer dissatisfaction. 4
Split seams during 4 customer useage Incorrect colour shade 3 tolerance specified
Control plan for sewing 4 Boundary samples derived Light box Customer sign off - Design studio. Fiat issued colour plaques Fiat spec for fabric. Build trials 8
64 96 0
32
Page 17 of 29
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Item #
S e v
4
C l a s s

O c c u r
2

Fiat spec for fabric. Build trials
D e R. t P. e N. c
4 32
Recommended Actions

0
31 Apearance /Seat system to provide design intent colours after design life of vehicle.
Seat system does not Customer provide design intent dissatisfaction. colours after design life of vehicle.
32 Appearance/Se Seat system does not provide required at system to styling. provide required styling
Incorrect design.
STO lines approval Prototype Builds Styling Reviews
24
4 4
Incorrect Trimmed A 4 surface Doming of top of seat 4 back between headrest bezels
STO vs scan line analysis Localised overbuild of foam around bezel apertures. Salvage groove at centre line to accommodate trim seams Review for prototypes Fiat spec for fabric, Fleet evaluation
3 3
48 48
33 Appearance/Se Seat system does not provide resistance to at system to seat cover soiling. provide resistance to seat cover soiling.
32
JCI to inform Fiat when material selected for program stains. Fiat to improve vehicle leak resistance.
Page 18 of 29
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Item #
S e v
5
C l a s s

Sticking height adjust lever
O c c u r
4
D e R. t P. e N. c
60
Recommended Actions

0
34 Appearance/Se at system to provide adjustment controls in design position prior and after use
Seat system does not Customer provide adjustment dissatisfaction. controls in design position prior and after use
Sticking track release lever
35 Seat system to Seat system does not provide a system free provide a system free of of BSR BSR
Excessive freeplay in 4 4 way height adjust system
Balanced 3 point fixing 3 of lever to clutch mech. Return spring operating aroung mechanism centre line. Clearance of 5 mm between lever and valance. Eval 1 Return spring on lever 2 Tolerance study for free movement of lever to housing Tolerance study 3 Reduce linkage interfaces Pre-tension system with assist spring. Bush pivot points as necessary 3 point retention of 2 handle to mechanism Distance of handle free end to valance Min 10 mm Tolerance study 3 Reduce linkage interfaces Clamp 5 dr version at 3 front with M10 to torque 45 - 50 Nm
16
48
4 way lifter handle contact with valance induced by vibration
24
Excessive freeplay in 5 Flip up cushion system Excessive freeplay in fsb system 4
60
48
Page 19 of 29
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Item #
S e v
4
C l a s s

Excessive freeplay in headrest system
O c c u r
4
D e R. t P. e N. c
48
Recommended Actions

0
Foam squeak against metal structure
Plunge apertures in 3 FSB frame at top and bottom locations Divorce bezel latching into frame from stem. Button system on one side of stem only Flat surface interaction 3 Corovin with location aids in Fsb Size for size foam agaist structure Sleeve springs 3 Angle claw ends to lift spring away from adjacent component edges Plastic insert in recliner 3 heart Lock top fixing into frame with pre-load Clearance of mat to frame through movement Tubular towel bar system with integral torque tube and end stops. (Pre-loaded tension) Vibration platform test Foot print tolerance control SC on GD & T controls Seat build fixtures to align with datum controls 3
48
Return spring vibration 4 form use and/or forced excitation
48
Recliner transmission rod freeplay within recliner heart FSB suspension mat contact with frame
48
48
Track release wire contact against adjacent components
36
4 4
Seat resonance Track misalignment resulting scrapping noise during fore/aft movement
3 3
3 4
36 48
Vehicle body tolerance agreement with Fiat
Page 20 of 29
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Item #
S e v
4
C l a s s

User adjustment lever rub against vinyl trim
O c c u r
4

Vinyl not to be specified against moving plastic handle or ornamentation Recliner lever effort Max. 4 Nm. (Update requirement with JCI target of 2 - 3 Nm. (SC 4 fwd -15 deg to + 15 deg. SC 5 rwd + 15 deg to -15 deg. Both taken either side of design posn) Recliner heart torque 0.9 Nm max GD&T with common datum for fixing locations Width across assembled seat at front marriage = 439 +/-1mm SC4(FSB dwg) Foot print control. Document footprint tolerance on complete seat drawings Foot print control. Document footprint tolerance and mounting sequence on complete seat drawings Provide 60 mm clearance zone around hand wheel. Buck package trials Agreement with Fiat if less than 60.
D e R. t P. e N. c
3 48
Recommended Actions
36 Efforts/Seat system to provide acceptable recline efforts
Seat system does not provide acceptable recline efforts
YS Friction, misalignments, incorrect geomety specified
84
YS Uneven floor mounting 5 in vehcle specified
140
YS User hand clearance intrusion from centre console
105
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Item #
S e v
7
C l a s s
O c c u r
3
D e R. t P. e N. c
42
Recommended Actions
37 Efforts/Seat system to provide acceptable height adjust efforts
Seat system does not provide acceptable height adjust efforts
Customer disatisfaction
YS User dificulty in activating due to incorrect size of handwheel YS Incorrect mechanical advantage
Use diameter of 80 mm 2 max
Free body diagram calculations. Use assist spring if necessary. JCI target of 65 +/- 20 N
42
7 38 Efforts/Seat system to provide acceptable track sliding efforts Seat system does not provide acceptable track sliding efforts Customer disatisfaction 7
YS Misalignment of track system YS Friction, misalignments, incorrect geomety specified
4 4
Foot print tolerance 3 control Individual slide effort 2 15 - 50 N Slide parallelism 2 mm Bolting sequence to body - As agreed with Fiat (Torque 24 - 28 Nm, M8 fixing) Track angle 2.0 deg. Foot print tolerance control Foot print control. 4 Document footprint tolerance and mounting sequence on complete seat drawings Packaging checks 2 package angle 2.0 deg. Target weight lower than existing seat structures 2
84 56
YS Uneven floor mounting 5 in vehcle specified
140
YS Package angle too steep YS Seat weight
56
28
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Item #

Seat system does not provide acceptable track handle efforts

S e v
4
C l a s s
O c c u r
D e R. t P. e N. c
24
Recommended Actions
39 Efforts/Seat system to provide acceptable track handle efforts
YS Incorrect 3 geometry/misalignment tolerance specified. Incorrect spring rates specified
Free body diagram 2 calculations. (handle effort 10-65 N. JCI target 50 +/- 15N Slide trigger spring rate Seat foot print tolerance documented on complete seat drawing. Vehicle floor body tolerance agreement with Fiat. Vehicle plant to record dimensional data on mounting locations between seat and vehicle body Provide min 35 mm between handle bar and vehicle floor Plunge top and bottom 6 holes in FSB frame. Latch bezel into frame with inner latch face away from running surface with rod. Prevent bulging around notch profiles. Control button spring efforts. target of 55 +/20 N
40 Efforts/Seat system to provide acceptable headtrest adjust efforts
Seat system does not Customer provide acceptable experiences headrest adjust efforts discomfort
SC Tolerance stack up of 4 frame, bezel, stem and button spring rate.
144
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Item #
S e v
6
C l a s s
O c c u r
3

Kinematic study, Surrogate system
D e R. t P. e N. c
4 72
Recommended Actions
41 Efforts/Seat system to provide acceptable flip up cushion release and closing efforts
Seat system does not Customer provide acceptable flip experiences up cushion release and discomfort closing efforts
SC Incorrect geometry
6 42 Handling/Seat system to provide adequate handling locations Seat system does not provide adequate handling locations Difficulty in handling the seat 5
SC Incorrect latch retention specified Sharp edges
3 4
JCI target effort 40 +/15 N Safe edge/de-burred edges in potential lift areas
6 2
108 40
0 0
Seat interferes with vehicle door aperture Headrest not removable
43 Serviceability/S Seat system does not permit economic eat system to servicing permit economic servicing
High replacement costs
2 Package/manufacturin g review - Fiat Bezel button with stem 2 notch detent dedicated user operation to remove Fiat workshop manual review Feature on bezel to aid 2 removal. Fiat workshop manual review Fiat workshop manual 2 review Fiat workshop manual 2 review
20
30
Headrest bezel not removable
30
5 5
Trim covers not removable Plastic covers not removable
3 3
30 30 Investigate method of releasing recliner handwheel without damage.
Page 24 of 29
/ STRIP VERSION
Item #
S e v
5
C l a s s

FSB not removable from tracks Unpainted/plated structure
O c c u r
3 3

Fiat workshop manual review Paint visible structure Headrest stems to be plated
D e R. t P. e N. c
2 2 30 24
Recommended Actions

0 0
44 Corrosion resistance/Seat system to resist oxidation of visible materials and structure in water ingress regions
Seat system does not resist oxidation of visible materials and structure in water ingress regions
Appearance compromised. Defect noticed by most customers.
45 Seat system to Seat system does not permit attachment to permit attachment to vehicle vehicle
Structual integrity 10 YC Unpainted/plated 5 compromised structure Cannot attach seat 8 SC No attachment feature 2 to vehicle on seat
Paint slide assemblies 6 Four off feet to accept 2 M8 fixing into body. Location pin in front feet Package review 2 Foot print control. Document footprint tolerance on complete seat drawings Control plan for 2 individual components, Surrogate system
300 32
0 0
SC Incorrect package specified
32
Seat system does not Customer 46 Efforts/Seat provide acceptable experiences system to headrest button efforts discomfort provide acceptable headrest button efforts 47 Feature/Seat system to provide underseat stowage Seat system does not provide underseat stowage Defect noticed by most customers
YS Incorrect spring rate and/or sliding clearances specified
36
No/incorrect mechanism specified for flip up seat.
BOM for component release Functional builds CAD kinematics Package checks
60
Page 25 of 29
/ STRIP VERSION
Item #
S e v
4
C l a s s

No stowage box specified.
O c c u r
3

BOM for component release Functional builds Package checks
D e R. t P. e N. c
3 36
Recommended Actions

0
Page 26 of 29
Process Failure Mode Effects and Analysis (PFMEA) Instructions

NOTE: Process FMEA's must be prepared for all programs (components, subassemblies and assemblies) where Johnson Controls has full program design responsibility. (A matrix for this purpose and the FMEA Form can be found in the AIAG APQP and Control Plan manual).
1.
INSTRUCTIONS: Process FMEA's are to be prepared using the DaimlerChrysler, Ford, and General Motors guidelines.
2.
All operations affecting fit, function, durability, governmental regulations and safety must be identified and listed sequentially. Similar part FMEAs must be considered.
3.
4.
Historical campaign, warranty data, high mileage and P-diagram data must be reviewed.
5.
Appropriate corrective actions must be planned and/or taken for high risk priority items (RPN 70 and greater). Appropriate corrective actions must be planned and/or taken for high severity numbers (severity of 7 and greater). Risk priorities numbers must be revised when corrective actions are completed.
6.
7.
8.
High severity numbers must be revised when a design change is completed.
9.
The effects must consider the customer in terms of the subsequent operation, assembly, and product.
10. Warranty information must be used as an aid in developing the Process FMEA.
11. Customer plant problems must be used as an aid in developing the Process FMEA.
12. The causes must be described in terms of something that can be fixed or controlled.
13. Where detection is the major factor, provisions must be made to control the cause prior to the next operation. 14. The PFMEA must identify and address all Special Characteristics (both significant and critical).
Page 27 of 29
POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA) FMEA Number: Item: Model Year(s)/Vehicle(s) __________________________ Team:
C Process # Process Function/ Requirements Potential Failure Mode Potential Effect(s) of Failure S e v l a s s Potential Cause(s)/ Mechanism(s) of Failure O c c u r Current Process Controls D e t e c R. P. N. Recommended Actions Responsibility & Target Date Actions Taken Action Results S e v O c c D e t R. P. N.
Process Responsibility: Key Date
Prepared by: Date (Orig.) Date (Rev.)
Page 28 of 29
Customer and Internal Special Char. Symbols

<tulip> <S> <S/C> <D> <P> North American Interiors ~Internal SC symbol Shield - DaimlerChrysler Safety Compliance - GM Diamond - DaimlerChrysler Pentagon - DaimlerChysler
CC or YC Critical Characteristic - Ford <F/F> Fit/Function - Ford
SC or YS Significant Characteristic
Page 29 of 29

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Design Failure Mode and Effects Analysis (DFMEA) Instructions

Item Function/ Requirements

Potential Failure Mode

Potential Effect(s) of Failure

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

Current Design Controls

Responsibility & Target Date

Action Results Actions S O D R. Taken e c e P. v c t N.

Incorrect gap size specified on flip up cushion system

Occupants 5 belongings fall into seat system

Item Function/ Requirements

Potential Failure Mode

Potential Effect(s) of Failure

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

Current Design Controls

Responsibility & Target Date

Action Results Actions S O D R. Taken e c e P. v c t N.

Ornamentation permits 3 objects to be funnelled into seat system

Occupant clothing 5 catches/snags 5

Fiat styling and package groups to agree on form and location.

Limited access to belt buckle. Foul condition to adjacent components.

Layout study. Prototype 3 evaluation

Pretensioner tube and 2 bracket clearance to console. CC Incorrect design. 1

Item Function/ Requirements

Potential Failure Mode

Potential Effect(s) of Failure

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

Current Design Controls

Responsibility & Target Date

Action Results Actions S O D R. Taken e c e P. v c t N.

SC Recliner handwheel grip area

SC Valance/recliner cover 2 edge

Seat belt damage. 9

Layout study. Prototype 1 evaluation Material specifications. 2 FMVSS 302.

Item Function/ Requirements

Potential Failure Mode

Potential Effect(s) of Failure

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

Current Design Controls

Responsibility & Target Date

Action Results Actions S O D R. Taken e c e P. v c t N.

YC Incorrect specification ofelectrical components.

YC Incorrect cable routing 1

YC Water ingress into connector system

Electrical system failiure.

Loss of electrical signal 3

5 Safety/Seat system to provide an ocupant with a protected environment.

System does not provide a protected environment for the occupant.

YC Headrestraint becomes 3 detached from seat structure

10 YC Incorrect material selection

Item Function/ Requirements

Potential Failure Mode

Potential Effect(s) of Failure

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

Current Design Controls

Responsibility & Target Date

Action Results Actions S O D R. Taken e c e P. v c t N.

YS Seat movemnts incomplete due to interference within structure

Kinematic studies in CAD, Prototype evaluation in vehicle

10 YC Flipup cushion self activates

Loss of 8 adjustment/feature function

YS Incorrect specification on material section

FEA 2 Free body diagrams Surrogate mechanisms

Item Function/ Requirements