POTENTIAL

FAILURE MODE AND EFFECTS ANALYSIS

Print # Rev. (PROCESS FMEA) FMEA Number:
Item: Process Responsibility: Prepared by:
Model Year(s)/Vehicle(s) Key Date Date (Orig.)
Team: Date (Rev.)
C Potential O D
Process Potential Potential S l Cause(s)/ c Current e R. Recommended Responsibility Action Results
Function/ Failure Effect(s) of e a Mechanism(s) c Process t P. Actions & Target Actions S O D R.
Require- Mode Failure v s of Failure u Controls e N. Date Taken e c e P.
ments (Process Defects) (Y's) s (X's) r c v c t N.
 POTENTIAL
FAILURE MODE AND EFFECTS ANALYSIS
Print # Rev. (PROCESS FMEA) FMEA Number:
Item: Process Responsibility: Prepared by:
Model Year(s)/Vehicle(s) Key Date Date (Orig.)
Team: Date (Rev.)
C Potential O D
Process Potential Potential S l Cause(s)/ c Current e R. Recommended Responsibility Action Results
Function/ Failure Effect(s) of e a Mechanism(s) c Process t P. Actions & Target Actions S O D R.
Require- Mode Failure v s of Failure u Controls e N. Date Taken e c e P.
ments (Process Defects) (Y's) s (X's) r c v c t N.
110-SCREEN PRINT Smudged Paste Shorts, Misplacement, Solderballs, 4 Handling damage 3 PCB Handling specified on MPI / 2 24
opens, Insuff. Training Procedure & Matrix /
V/I-150-Feedback
Damaged stencil 2 Stencil Check Specified on MPI / 1 8
Training Procedure & Matrix / SPC/
FAI-AF143 / MPI & IC 110 Visual Check
Tooling block not located 8 Set-up verification / FAI-AF143 1 32
correctly
Printer not maintained properly. 3 Training Procedure & Matrix / 3 36
PM Schedule
Set-up verification / FAI-AF143 / IC-110 Visual
Autowipe not functioning
2 Check 3 24
Wrong Paste Contamination, solder - quality, 8 Wrong paste requested 2 Specified on MPI / FAI-AF143 5 80
mixed chemistry
Wrong paste issued 2 Specified on MPI / FAI-AF143 1 16
MOF012 Form
Wrongly labelled 2 Receiving Inspection. 2 32
Missing Paste Opens, Missing and misplaced 5 Blocked apertures in stencil 2 Training Procedures & Matrix / 2D Inspect 2 20
components. MPI & IC 110 Visual Inspect / SPC / FAI-AF143
Damaged stencil 2 Stencil Check Specified on MPI / 2D Inspect 1 5
Training Procedure & Matrix / SPC/
FAI-AF143 / MPI & IC 110 Visual Check
Wrong stencil 2 Specified on MPI / FAI-AF143 / 1 10
MPI & IC Visual Inspect / 2D Inspect
Paste sticking to squeegee blades 4 Training Procedure & Matrix / SPC 3 60
2D Inspect
Squeegee blades too short 2 Training Procedure & Matrix / 2D Inspect 3 30
Check Specified on MPI / SPC / FAI-AF143
Printer stroke too short for screen 2 Set-up verification / FAI-AF143 / 2D Inspect 1 10
Training Procedure & Matrix / FAI-AF143 / MPI &
Insufficient Past Loaded 4 IC 110 Visual Check / 2D Inspect 3 60
Mis-registration Shorts, Opens, Solder Balls 6 Printer wrongly set-up 2 Set-up verification / FAI-AF143 2 24
Missing, misplaced comp. MPI & IC Visual Check
Warped/Wrongly dimensioned MPM - Clamp & Support / MPI & IC Visual
PCB's 3 Inspect 3 54
Stretched stencil 2 FAI-AF143 / MPI & IC Visual Inspect 2 24
Wrong block support 3 Set-up verification / FAI-AF143 4 72
PCB not loaded properly into 2 Training Procedure / Matrix / Visual 1 12
printer Inspect MPI & IC 110
Contamination Solderballs, Opens, Poor Solder quality, 6 Incorrect handling of PCB 3 Handling Specified on MPI / 3 54
Scrap V/I-150-Feedback/
Training Procedure & Matrix
Wrong paste used 2 Specified on MPI / FAI-AF143 4 48
MOF012 Form
Dirty block support 3 Training Procedure & Matrix / 3 54
Feedback from View & Improve
Weekly Audit introduced - MOF020
Wrong cleaning fluid in printer 2 None Required 7 84
Wiped cards, not cleaned properly 3 Cleaning Instructions on MPI 3 54
MPI states inspection of washed cards.
Paste out of" use by" date 1 Receiving Inspection / FAI-AF143 / 1 6
Procedure - MC0007
Process machines not clean 4 Training Procedures & Matrix 2 48

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 Weekly Audit introduced - MOF020
Set-up verification / FAI-AF143 / IC-110 Visual
Autowipe not functioning 2 Check 3 36

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 Bridging Shorts, Solderballs. 2 Damaged stencil 2 Stencil Check Specified on MPI / Training 1 4
110-SCREEN PRINT Procedure & Matrix / SPC/ FAI-AF143 / MPI & IC
(cont). 110 Visual Check
Wet screen 2 Training Procedures & Matrix 1 4
Visual Inspection
Poor gasket between screen and 2 Set-up verification / FAI-AF143 2 8
PCB
Insufficient Squeegee 2 MPI & IC 110 Visual Inspect / SPC / 3 12
Pressure Feedback from View & Improve /
FAI-AF143
Print speed too fast 2 Feedback from View & Improve / 4 16
FAI-AF143
Too much paste 3 Training Procedure & Matrix / SPC / 2 12
MPI & IC 110 Visual Inspect
FAI-AF143
Wrong aperture size on stencil 1 FAI-AF143 / Feedback from View & 2 4
Improve
Wrong stencil thickness 2 Training Procedures & Matrix / 1 2
Specified on MPI
Squeegee damaged 3 Training Procedure & Matrix / 2 12
Check Specified on MOI
Wrong squeegee material 2 Training Procedure & Matrix / 2 8
Specified on MPI
125-SMT MACHINE Misplacement Rework, test fails and scrap 7 Faulty feeders 4 Feeder maintenance and 2 56
PLACEMENT inspection feedback
(Placement Of Wrong feeder / pitch 3 Training procedure / matrix 3 63
Components Onto Attrition Report
Pasted Card) Incorrect program / revision 4 Head set-up check and 2 56
FAI-AF143
Incorrectly shaped part / Pd 3 FAI-AF143, NPI assessment at 2 42
start up, on-going Attrition Reports
Damaged / wrong nozzle 3 Centre check, machine self diagnosis test / 3 63
FAI-AF-143 / V/I-150-Feedback, Melf Nozzles
Board not clamped in machine 4 Set-up verification, and 3 84
FAI-AF143
Wrongly set-up board supports 4 Set-up verification. 2 56

Dry paste on boards 2 V/I-150-Feedback 4 56

Missing components Rework, test fails and scrap 4 Faulty feeders 4 Feeder maintenance & calibration, Attrition 2 32
report and inspection feedback
Wrong feeder / pitch 4 Training procedure / matrix 2 32
Incorrect program / revision 4 Head set-up check and 2 32
FAI-AF143
Incorrectly shaped part / Part 3 FAI-AF143, NPI assessment at 2 24
Data start up, on-going Attrition Reports
Damaged, wrong nozzle 1 Centre check, machine self 2 8
diagnosis test and FAI-AF143
Board not clamped in machine 3 Set-up verification, and 3 36
FAI-AF143
Wrongly set-up board supports 4 Set-up verification. 2 32

Dry paste on boards 2 Feedback from View & Improve 4 32

Machine interrupted during cycle 1 Training Procedure / Matrix 2 8
Feedback from View & Improve
Faulty spool valves( cp only ) 1 Preventative maintenance / 2 8
Feedback from View & Improve

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125-SMT MACHINE Incorrect part Rework, test fails and scrap 7 Wrong part placed on machine 2 Barcode scanner, verification by op 3 42
PLACEMENT headset-up and FAI-AF143
(cont). Program Error 2 FAI-AF143 2 28
Reel labelled incorrectly by 2 Receive and inspection and FAI-AF143, 2 28
supplier V/I-150-Feedback
FCT Test / Machine Vision
Reel labelled incorrectly by 2 Receive and inspection and FAI-AF143, 2 28
stores V/I-150-Feedback
Wrong program / rev. 2 Head set-up check / FAI-AF143 2 28
FCT Test / Specified on MPI
Reversed part Test fails / rework 7 Wrongly packaged from supplier 3 Receive and Inspection / FCT / 2 42
FAI-AF143 / View and Improve
Tray placed incorrectly in I.P.3 2 Head set-up check, FAI-AF143, training 2 28
procedure / matrix, V/I-150-Feedback.
Program Error 2 Head set-up check, FAI-AF143 2 28
Set-up verification / Specified on MPI
Set-up verification / FAI-AF143 / View &
Damaged parts Test fails / rework 5 Wrongly set-up board supports 2 Improve / FCT Test / FQC 5 20
Incorrect Assembly Height 2 Set-up verification / FAI-AF143 / 2 20
140-REFLOW Warped cards Scrap 6 Incorrect profile setting 2 Profile oven, MPI, FAI-AF143, Inspection 2 24
set-up verification and P.M
Incorrect track width 3 Profile oven, Inspection and 2 36
set-up verification

Incorrect centre support rail setting 4 MPI, FAI-AF143, Inspection, set-up verification 2 48
Misplaced parts Rework, test fails and scrap 7 Incorrect profile settings 2 Profile oven, MPI, FAI-AF143, Inspection 2 28
set-up verification and P.M
Faulty profile card 1 Profile oven, MPI, FAI-AF143, Inspection 2 14
and set-up verification.
Faulty heater 1 Profile Oven, 2 14
Auto shut down
Faulty fan 2 Profile Oven, P.M. and 2 28
Auto shut down

Transport error 2 FAI-AF143, Inspection and set-up verification. 1 14

Paste not reflowing Rework, test fails and scrap 7 Incorrect profile settings 2 Profile oven, MPI, FAI-AF143, Inspection 2 28
set-up verification and P.M
Faulty profile card 1 Profile oven, FAI-AF143, Inspection 2 14
and set-up verification.
Faulty heater 1 Profile Oven, Auto shut down 2 14
Faulty fan 2 Profile Oven, P.M. and 2 28
Auto shut down
150-VIEW/IMPROVE Reject good cards. Unnecessary repairs, potential damage. 2 Inadequate training to standards 3 Training procedure / Matrix and Yearly 5 30
Visual Inspection Of PCB
assessments / Final Inspect / Sample Audit /
Assemblies
FCT Test
Inspect to IPC Class 3. Training procedure / Matrix and Yearly
1st & Last off value check Customer returns, Incomplete verification of assessments / Final Inspect / Sample Audit /
required. Accept bad cards product. 3 Inadequate training to standards 3 FCT Test 2 18

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