POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS IN MANUFACTURING AND ASSEMBLY PROCESSES FMEA Number MM-2000 (PROCESS FMEA)
Item MM-2X Model Year(s)/Program(s) 2001/N/A Core Team Sam and Janet Eveling
Process Function
Process Responsibility Goodson Key Date 4/24/2001
Prepared By R. Yates/867-5309 FMEA Date (Orig.) 2/2/1999 (Rev.) 03/02/2001
Potential Failure Potential Effect(s) of Mode Failure
S e v
Class
Potential Cause(s)/ Mechanism(s) of Failure
O c c
Requirements
Current Process Controls - Prevention - Detection
D e t
R P N
Recommended Action(s)
Resp. & Target Compl. Date
Action Results
Actions Taken
S e v
O c c
D e t
R P N
010 - Wind wire around index finger 001 - Coil diameter
Diameter too large - Coil hits battery during operation - Rotor is short because too much material is used in coils Diameter too small - Weak motor - Difficult removal from finger Diameter too large - Coil hits battery during operation - Rotor is short because too much material is used in coils Diameter too small - Weak motor - Difficult removal from finger
Wire wound loosely
3 >Char Control 1: Measure with gage.
96 None
None
Finger too small
72 None
None
Finger too large
120 None
None
Wire wound tight
002 - # of coils Too few coils
- Motor too weak
Operator miscounts
- Rotor too short to reach supports - Motor too powerful - Wasted material 110 - Coil Starting position - Opposing wire end starting position too incorrect (long too short to reach or short) support - Not enough wire to wind all coils
Too many coils
Not enough wire Operator miscounts
2 >Char Control 1: Operator counts number of coils out loud. 3 2
144 Provide operator with a tool for grasping the wire that limits the tension. 30 None
Tool Engineering 6/6/1999
Tool developed, tested, and implemented at process step 010. None
54
4 3
60 None 48 None
None None
Light dim so ruler hard to read
2 >Char Control 1: Use ruler to locate start position.
42 None
None
Ruler worn so hard to read
63 None
None
4/5/2001 12:21:30 PM
PFMEA MM-2000
This is not a controlled document
Page 1 of 2
POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS IN MANUFACTURING AND ASSEMBLY PROCESSES FMEA Number MM-2000 (PROCESS FMEA)
Item MM-2X Model Year(s)/Program(s) 2001/N/A Core Team Sam and Janet Eveling
Process Function
Process Responsibility Goodson Key Date 4/24/2001
Prepared By R. Yates/867-5309 FMEA Date (Orig.) 2/2/1999 (Rev.) 03/02/2001
Potential Failure Potential Effect(s) of Mode Failure
S e v
Class
Potential Cause(s)/ Mechanism(s) of Failure
O c c
Requirements
Current Process Controls - Prevention - Detection
D e t
R P N
Recommended Action(s)
Resp. & Target Compl. Date
Action Results
Actions Taken
S e v
O c c
D e t
R P N
020 - Slip wound wire off finger 111 - Maintain Rotor mis-shapen rotor shape 030 - Sand coating off wire ends 004 - Length of Bare wire too long coating removed Bar wire too short 113 - Sanding Sanding time too time long Sanding time too short 040 - Store finished wire (rotor) 100 - Maintain Lot ID lost lot ID 111 - Maintain Rotor mis-shapen rotor shape 050 - Bend clips to make supports 005 - Rotor Support missupport shaped shapen like print 060 - Store rotor supports 100 - Maintain Lot ID lost lot ID 112 - Maintain Support missupport shape shapen
None
None
0 0 0 0
None None None None
None None None None
0 0
None None
None None
None
None
0 0
None None
None None
4/5/2001 12:21:31 PM
PFMEA MM-2000
This is not a controlled document
Page 2 of 2
