pfmea example

Failure Mode and Effects Analysis

Sheet1CUSTOMER LISTFMEA LISTSACTIVE # IN DOCUMENT1SEVERITY SCALE1GM10 Hazardous - w/o warning2FORD9 Hazardous - w/ warning3CHRYSLER8 Very High47 High56 Moderate65 Low74 Very Low83 Minor92 Very Minor101 None11OCCURENCE SCALE1210 >1 in 2139 1 in 3148 1 in 8157 1 in 20166 1 in 80175 1 in 400184 1 in 2,000AIA193 1 in 15,000202 1 in 150,0001 1 in 1,500,000DETECTION SCALE10 Absolute Uncertainty9 Very Remote8 Remote7 Very Low6 Low5 Moderate4 Moderately High3 High2 Very High1 Almost Certain

Document ControlDocument #:14444800Program:Template - Peel and Stick Heater PFMEAModel Year:N/ARFQ # / Basis #:N/ABack Office Chief / ManagerDeana BorghiBack Office LeadJoe HebdaProgram ManagerRobert HicksPhase:N/AECO #:Rev:Change Description:Date:AInitial Release

&L&G&CSupplier Standards ManualSeat Heat Peel and Stick Heater PFMEAChapter 7 Quality SectionMarch 2008 Revision 1.0&L&F&RPage &P of &N

RevisionsCORE PFMEA SHEET - SEAT HEATERSItemDateRevisions1.10/282003Converted Document from MPACT to Excel.2.2/4/04Updated with Password Protections, Added Revision Tab, Updated PFMEA Instruction, Created Separate Tabs for Peel N' Stick and Sewn-In Systems.3.9/14/04Updated document with Significant and Critical symbols - Sept 044.9/9/05Updated to reflect revised operational procedures & new Design template.


PFMEA InstructionProcess Failure Mode Effects and Analysis (Heater PFMEA) InstructionsAll 2007 model year and beyond programs must utilize Heater Template.NOTE: Process FMEA's must be prepared for all programs (components, subassemblies and assemblies) where Johnson Controls has full program design responsibility. (Refer to the AIAG FMEA Manual and the AIAG APQP and Control Plan manual).Instructions for PEEL N' Sticker Heater PFMEA Template :1.Process FMEA's are to be prepared using a cross functional team and the AIAG Potential Failure Modes and Effects Analysis (FMEA) manual.The cross-functional team should include: * Advance Manuf. Engineer (Champion)......PFMEA from similar programs, DFM&A input* Product Engineer .................................DFA items for similar programs* Quality Engineer .........................2.Copy Information from the "Heater_Template" into your existing PFMEA.xls file where you process the heater elements. Steps 1-5 should be copied into the area where the heater to foam operation occurs. The remaining steps should be incorporated into the seat build process at the appropriate operational step. (NOTE: REVIEW BOLD TEXT to determine if items apply to processing)3.Occurrence numbers can be adjusted by the Cost Functional Team based on Customer Plant Problems or Warranty Information. These items should be listed in the Recommended Actions Column and used to re-calculate the RPN under the "Reaction Results"4.Detection numbers can be adjusted by the Cost Function Team based on Controls not listed under the Detection/Prevention Columns. These items should be listed in the Recommended Actions Column and used to re-calculate the RPN under the "Reaction Results"


Peel N Stick HeaterCORE SEAT HEATER P F M E AFAILURE MODE AND EFFECTS ANALYSISControl PlanFMEA no#:PrototypePre-launchProductionKey Contact/PhoneDate (Orig.)Date (Rev.)Item/Component:PEEL N' STICK HEATERSOEMPrepared by:CoE OrganizationControl Plan NumberModel Year/Vehicle:Key Date:Part Number/Latest Change LevelCore TeamCustomer Engineering Approval/Date (If Req'd)CoreTeam:FMEA Date (Orig.)FMEA Date (Last rev.)Part Name/DescriptionSupplier/Plant Approval/DateCustomer Quality Approval/Date (If Req'd)S E VCLASSPotentialOCCURStandardStandardDETECTR P NAction ResultsSupplier/PlantSupplier CodeOther Approval/Date (If Req'd)Other Approval/Date (If Req'd)ItemProcess Function/PotentialPotentialCause(s)/ProcessProcessRecommendedResponsibility#RequirementsFailureEffect(s) ofMechanism(s)ControlsControlsActions& TargetActionsSODR.Part /Process Name /Mach, Device,CharacteristicsSpecialMethodsModeFailureof FailurePreventionDetectionCompletionTakeneceP.ProcessOperationJig, ToolsNo.ProductProcessChar.Product / ProcessEvaluationSampleControl MethodReactionDatevctN.NumberDescriptionFor Mfg.Class.Specification/ToleranceMeasurement TechniqueSizeFreq.Plan1Get componentswrong partsimproper heating locations5a. Wrong components stocked on line2a) Lineside racking with designated lanesb) Labeled containers from supplier w/part description660b. picked up from the floor, another bin, etc (other than the correct location)2plant procedure for part handling re. loose parts, operator training660c. similar component used in the same station (picked up the wrong component)2separation of LH & RH seats/ components660d. Wrong components in the correct shipping container (Supplier Issue)11050Obtain the correct components but not to the required design standardsnon-functioning heater or improper heating locations6a. box cutter cut through element wire/ harness when opening box2a) Prohibit opening box with cutter/ caution label added to packagingb) returnable packaging c) special designed heater packaging (egg-crate) to prevent failureEOL tester - Check Current Draw (Applies to Series System)448b. Component picks up foreign materials or comes in contact with (especially with the adhesive tape)1ODS, (Reject procedures)742c. FIFO is not conducted1FIFO Procedures utilized at facility, Change Management, Material Inventory management procedures100% visual inspection at point of installation to a master sample742d. previously used component is used1ODS, (Reject procedures)742e. carrying by harness (peel & stick heater)1ODS, trainingEOL tester - Check Current Draw424f. hanging parts to pre-stage at station2Incoming part racking, Proper material containerEOL tester - Check Current Draw448Hot Spot in the harness9a. Box cutter when opening box (If nick is between module and heater sensor in the element)1a) Prohibit opening box with cutter/ caution label added to packagingb) returnable packaging c) specially designed heater packaging (egg-crate) to prevent failure763b. Dangling harness get snagged by equipment, tools fixtures causing nick2a) plant procedure for part handling re. loose partsb) equipment designEOL tester - Check Current Draw472Wrong sub-assembly placed on seat (subasm out of sequence)Non-functional heaterNo heater on seat6No heater mat on heated seat, or heater mat on non-heated seat2ODS, Operator training matrix,7842Align heater pad to foam pad.Installed off location/ mis-alignmentnon-symmetrical heating

difficult to install hog rings3a. ODS elements are not followed.3Operator training matrix,visual inspection for notch alignment7630b. ODS is not clearly defined for operator to follow3Operator training matrix,visual inspection for notch alignment763c. Lack of alignment between heater element and foam pads (insufficient installation reference points / datums)2Operator training matrix, DFA Review, Safety Sign offvisual inspection for notch alignment742Only Applies if Elements Cross over Trenches in local spots.damage to heater wire causing short or hot spot10HICa. Wire positioning in trench (too much causing 'bending' effect under compression, not enough causing strain, or positioned such that damage can occur during hog ring installation)1ODS, trainingEOL tester- ground detection7703Remove tape backing from adhesive.Installed off location/ mis-alignmentnon-symmetrical heating

difficult to install hog rings3a. ODS elements are not followed.3Operator training matrix,visual inspection for notch alignment7630b. ODS is not clearly defined for operator to follow3Operator training matrix,visual inspection for notch alignment763c. Lack of alignment between heater element and foam pads (insufficient installation reference points / datums)2Operator training matrix, DFA Review, Safety Sign off742Only Applies if Elements Cross over Trenches in local spots.damage to heater wire causing short or hot spot10HICa. Wire positioning in trench (too much causing 'bending' effect under compression, not enough causing strain, or positioned such that damage can occur during hog ring installation)1ODS, trainingEOL tester- ground detection770Heat elements not adhered to the foam properlyelement moves and may bunch heater elements causing hot spots10HICa. Reuse of heater element (adhesive is one time use)1ODS, training, reject procedurevisual, seat appearance7700b. All tape backing not removed or partially removed or torn3ODS, trainingvisual, seat appearance7210Implement a tape backing design that has pull tabs for the operator.refer to product design template101770c. Adhesive comes in contact with foreign materials (dust, dirt, oils, etc)1ODS (Reject procedures)770d. Tape to felt adhesive joint separates (as operator removes tape backing)1Operator training matrix,7704Attach heater pad to foam pad.Installed off location/ mis-alignmentnon-symmetrical heating

difficult to install hog rings3a. ODS elements are not followed.3Operator training matrix,visual inspection for notch alignment7630b. ODS is not clearly defined for operator to follow3ODS approval procedure, Operator training matrix,visual inspection for notch alignment763c. Lack of alignment between heater element and foam pads (insufficient installation reference points / datums)2Operator training matrix, DFA Review, Safety Sign off742Only Applies if Elements Cross over Trenches in local spots.damage to heater wire causing short or hot spot10HICa. Wire positioning in trench (too much causing 'bending' effect under compression, not enough causing strain, or positioned such that damage can occur during hog ring installation)1ODS, trainingEOL tester- ground detection770Heat elements not adhered to the foam properlyelement moves and may bunch heater elements causing hot spots10HICa. Reuse of heater element (adhesive is one time use)1ODS, training, reject procedure7700b. not firmly pressed down to engage adhesive1ODS, trainingvisual, seat appearance770c. Adhesive comes in contact with foreign materials (dust, dirt, oils, etc)1ODS, (Reject procedures)visual, seat appearance770Heater element not installed flatwrinkling of element causing hot spots10HICa. ODS elements are not followed.1Operator training matrix,visual, seat appearance770b. ODS is not clearly defined for operator to follow1Operator training matrix,visual, seat appearance770c. Lack of alignment between heater element and foam pads1Operator training matrix, DFA Review, Safety Sign offvisual inspection for notch alignment770d. Foreign object trapped under heater mat1Operator training matrix, scrap procedurevisual, seat appearance770e. Heater mat folds over on itself (sticks to itself once backings are removed1Operator training matrixvisual, seat appearance7705Route wire harness through foamImproper routingdamage to harness, causing improper heating function6a. ODS elements are not followed.1Operator training matrix,visual, seat appearance742b. ODS is not clearly defined for operator to follow1Operator training matrix,visual, seat appearance7426Convey/ transport s/a (ONLY APPLIES IF FOAM/HEATER ELEMENT IS NOT INSTALLED AT THE SAME STATION AS TRIM COVER)Components not properly conveyed/ transporteddamage to harness, causing improper heating function6a. Dangling harness snagging equipment, tools, fixtures2tucking harness into asm for transportationEOL tester - Check Amp draw448c. Heater element is used as "handle" for carrying2ODS, trainingEOL tester - Check Amp draw448bunching of heater causing hot spots10HICa. Pulling on dangling wire harness during conveying1ODS, trainingvisual, seat appearance880b. Tape not firmly pressed down to engage adhesive1ODS, trainingvisual, seat appearance7707Attach trim cover to foamHeater off location/ mis-alignmentdamage to jumper wire/ heating element causing short or hot spot10HICa. Hogring nicks heater wire (Applies only if attaching trim cover with Hog Rings)2ODS, trainingEOL tester- ground detection480b. Hog ring is not shot through clearance hole in heater mat2ODS, trainingvisual, seat appearance8160Heater moves during assemblybunching of heater causing hot spots10HICa. Pulling on wire harness1ODS, trainingvisual, seat appearance880b. Excessive Finessing of the trim cover1ODS, trainingvisual, seat appearance880Only Applies if Using Back Stuffer or Cushion Roller to attach Trim Coverc. Roller Stanchions catch corners/edges of the heater element1ODS, trainingvisual, seat appearance880d. Trim covers catches corners/edges of the heater element1ODS, trainingvisual, seat appearance880e. Poor adhesion between pad and Element2ODS, trainingvisual, seat appearance7140Revise adhesive material to meet current design template pulloff requirementEngineering1017708Convey/ transport s/a (ONLY APPLIES IF FOAM/HEATER ELEMENT/FOAM IS NOT INSTALLED AT THE SAME STATION AS TRIM COVER IS ATTACHED TO CUSHION OR BACK)Components not properly conveyed/ transporteddamage to harness, causing improper heating function6a. Dangling harness snagging equipment, tools, fixtures2tucking harness into asm for transportationEOL tester - Check Amp draw448b. Asm is folded or bunched1ODS, Training742c. Heater element is used as "handle" for carrying2ODS, trainingEOL tester - Check Amp draw448bunching of heater causing hot spots10HICa. Pulling on wire harness during conveying1ODS, trainingvisual, seat appearance880b. Asm is folded or bunched1ODS, trainingvisual, seat appearance8809Route & secure wire harnessImproper routing (places harness between hard points)pinched / cut wire harness causing short condition6a. Exposure to hard points1Operator training matrix, DFA reviewvisual, seat appearance742Not secured (which may place harness in harms way over time)pinched / cut wire harness causing short condition6a. High insertion forces on retaining clips2ODS sheets and Operator Training.audible, tactile, or visual indicator784b. Inadequate clearances2DFA Workshops784c. ODS Elements are not followed1Operator training matrix,742d. ODS is not clearly defined for operator to follow1Operator training matrix,74210Connect back element to cushion element (ONLY APPLIES IF SYSTEM HEATS BOTH BACK AND CUSHION)Not connectedimproper functioning heater system6a. ODS elements are not followed. (wire routed improperly)1Operator training matrix,EOL tester - Check Amp draw after full seat travel4240b. ODS is not clearly defined for operator to follow1Operator training matrix,EOL tester - Check Amp draw after full seat travel424Not fully connectedintermittent operation5a. High insertion forces2ODS sheets and Operator Training.audible, tactile, or visual indicator770b. Inadequate clearances to complete task2DfA Workshops, Manufacturing Reviews770c. Lack of indication for complete engagement2ODS sheets and Operator Training.operator push-pull-push connect method440d. ODS Elements are not followed1Operator training matrix,735e. ODS is not clearly defined for operator to follow1Operator training matrix,73511Connect to seat wire harnessNot connectednon-functioning heater6a. ODS elements are not followed.1Operator training matrix,EOL tester - Check Amp draw after full seat travel4240b. ODS is not clearly defined for operator to follow1Operator training matrix,EOL tester - Check Amp draw after full seat travel424Not fully connectedintermittent operation5a. High insertion forces2ODS sheets and Operator Training.audible, tactile, or visual indicator770b. Inadequate clearances to make connection2DFA Workshops, Manufacturing Reviews770c. Lack of indication for complete engagement2ODS sheets and Operator Training.operator push-pull-push connect method440d. ODS Elements are not followed1Operator training matrix,735e. ODS is not clearly defined for operator to follow1Operator training matrix,735Improperly connected to mating connectornon-functioning heater6a. similar connector on seat harness (Lack of poka-yoke of harness connectors2DFA Workshops, Manufacturing Reviews, Design reviewsEOL tester- amp draw check448b. ODS Elements are not followed1Operator training matrix,742c. ODS is not clearly defined for operator to follow1Operator training matrix,74212Connect to seat wire harness to Heat Module or switchNot connected (APPLIES ONLY IF HEATER MODULE IS ASSEMBLED AT THE JIT)non-functioning heater6a. ODS elements are not followed.1Operator training matrix,EOL tester - Check Amp draw after full seat travel4240b. ODS is not clearly defined for operator to follow1Operator training matrix,EOL tester - Check Amp draw after full seat travel424Not fully connected (APPLIES ONLY IF HEATER MODULE IS ASSEMBLED AT THE JIT)intermittent operation5a. High insertion forces2ODS sheets and Operator Training.audible, tactile, or visual indicator770b. Inadequate clearances to make connection2DFA Workshops, Manufacturing Reviews770c. Lack of indication for complete engagement2ODS sheets and Operator Training.operator push-pull-push connect method440d. ODS Elements are not followed1Operator training matrix,735e. ODS is not clearly defined for operator to follow1Operator training matrix,735Improperly connected to mating connector (APPLIES ONLY IF HEATER MODULE IS ASSEMBLED AT THE JIT, Severity to be confirmed by Engineering)non-functioning heater and/or disables Heater Module Functions (Over Heats)8a. similar connector on seat harness (Lack of poka-yoke of harness connectors2DFA Workshops, Manufacturing ReviewsEOL tester- amp draw check464b. ODS Elements are not followed1Operator training matrix,756c. ODS is not clearly defined for operator to follow1Operator training matrix,756Module is properly connected but damaged by process (APPLIES ONLY IF HEATER IS PART OF HEATER SYSTEM, Severity to be confirmed by Engineering)Non-Functioning heater system and/or disables Heater Module Functions (Over Heats)8a. Module is dropped2Reject Procedure, Repair procedureEOL tester- amp draw check464b. Module comes in contact with a Static Discharge2Reject Procedure, Repair procedureEOL tester- amp draw check464c. Module see a Voltage Spike2Reject Procedure, Repair procedureEOL tester- amp draw check464d. Module see a reverse voltage polarity.2Reject Procedure, Repair procedureEOL tester- amp draw check46413Function testingnot tested / tested improperlyshipment of a non-functional heated seat6a. Equipment failure2Operator training matrixwarning lights, current draw (amperage)224b. Damage to connector during the function test2ODS, training, Reject Procedure, Repair procedure, pogo pin connectors89614Transfer Seat to Ship PalletTransfer Equipment/Method damages of heater element/ harnessinoperable heater6a. Improper handling of seat1seat lift assist to transfer seat from build line to pallet954b. Lift assist tool is placed in location where wire harness / seat element is routed1DFA Workshops, Manufacturing Reviews848

&L&G&CSupplier Standards ManualSeat Heat Peel and Stick Heater PFMEAChapter 7 Quality SectionMarch 2008 Revision 1.0&L&8FBU PFMEA Heater Template / Rev 02 (15-December-2004)&Cfile name: &F&R&8Page &P of &N&L&8PFMEA Heater Template / Rev 03 (29-September-2004)&Cfile name: &F&R&8Page &P of &N

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