POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS & CONTROL PLAN.

Stage: Prototype Pilot Safe Launch Production

Created: Revision date:
Number of potential
Part No.: Edition: failure modes:
Ppap Id:

Core Prepared: Quality Assurance: Engineering:

Team Approved: Quality System: Production:

This document consists only of the creation according to the FMEA-4 Manual: 2008 published by AIAG. The only official document is the one published by AIAG itself.
 Prototype Pilot Safe Launch Production
PFMEA Champion:
CP Champion:
POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)
CONTROL PLAN (CP)
Part Name: EMZ Line: Part Name: EMZ Line:
Part Number: Submission Date: 7/11/2017 Revision: A Part Number: Submission Date: 7/11/2017 Revision: A
Supplier Name: Supplier Core Team: Supplier Name: Supplier Core Team:
Characteristic

Characteristics

Ocurrence

Ocurrence

New RPN
Significant

Detection

Detection
Severity

Severity
Responsibility & Actions Taken / Significant
Process Name / Measurement Sample Responsible* Related Poka

RPN
Process No. Process requirement / Functions No. Potential Failure Mode Potential Failure Effect Potential Cause(s) of Failure Prevention control Detection control Recommended Actions Target Completation Completation Process No. Characteris Machine/Device/Tool Specification Tolerance Frecuency Control method Control record Reaction Plan
Operation Description. No. Product Process Method size * Documents Yoke
date Date tics*

0 0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

(*1)Significant Characteristics (*)Significant Characteristics (**)Responsible

● Cpk Critical CPK 2.0 ● Cpk Critical CPK 2.0 I Operator
● Critical ● Critical II Inspector
◐ Mayor ◐ Mayor III Engineer
⭕ Relevant ⭕ Relevant IV Supervisor
Standard V Sub. Manager
VI Manager

2/4
 (Table 1) Reference Criteria; Severity Rank
Rank Effect Refer
10 Hazardous safety or Without warning, but the failure mode causes hazardous safety or viola
violation of
9 regulations/laws With warning, but the failure mode causes hazardous safety or violation
8 Hazardous vehicle Reduced vehicle (or system) critical functionality, level of performance
7 critical functionalities Reduced vehicle (or system) critical functionality, level of performance
6 Negative vehicle Vehicle (or system) functionality, level of performance and comfort are
5 functionalities Vehicle (or system) functionality and level of performance are reduced.
4 Customer's Discriminating customers (more than 75%) notice uncomfortable fit &
3 uncomfortable / Discriminating customers (more than 50%) notice uncomfortable fit &
2 inconvenience Discriminating customers (more than 25%) notice uncomfortable fit &
1 No effect No effect for customers.

(Table 2) Reference Criteria; Occurrence Rank

Referen
Rank Probability of Failure
Cpk
Very High
10 ＜0.33
(Continuously occur)
9 ≧0.33
High
8 ≧0.50
(Often occur)
7 ≧0.67
6 ≧0.83
5 Moderate ≧1.00
4 ≧1.17
3 ≧1.33
Low
2 ≧1.50
1 Very Low ≧1.67

(Table 3) Reference Criteria; Detection Rank

Likelihood of
Rank Refere
Detection
10 Almost Impossible There is no known process control to detect the failure.
9 Very difficult It is very difficult to detect the failure by use of the current process cont
The failure is not detectable at the objective process, but very low chan
8 Very Low
process.
7 Low chance operator-dependent process control such as
Low
6 Moderately low chance the failure is detectable by use of
5 Moderate Moderately chance the failure is detectable by use of gauges at the obje
4 High chance the failure is detectable by automated process control at th
High
3 High chance the failure is detectable by automated process control at th
2 Very High Very high chance the failure is detectable by automated process control
1 Certain The robust process control certainly detects the failure. There is no chan

(1) R.P.N.(Risk Priority Number)

Fill in Risk Priority Number that is calculated by "R.P.N." = S x O x D.

(2) recommended actions

Fill in determined action plan to reduce RPN according to SQM.
 Reference Criteria; Severity (S) Rank
Without warning, but the failure mode causes hazardous safety or violation of regulations/laws.
With warning, but the failure mode causes hazardous safety or violation of regulations/laws.
educed vehicle (or system) critical functionality, level of performance cause a sever accident.
educed vehicle (or system) critical functionality, level of performance has possible risks to occur a sever accident.
ehicle (or system) functionality, level of performance and comfort are reduced. Customers experience dissatisfaction.
ehicle (or system) functionality and level of performance are reduced. Customers experience some dissatisfaction.
iscriminating customers (more than 75%) notice uncomfortable fit & finish or squeak & rattle.
iscriminating customers (more than 50%) notice uncomfortable fit & finish or squeak & rattle.
iscriminating customers (more than 25%) notice uncomfortable fit & finish or squeak & rattle.
o effect for customers.

Reference Criteria; Occurrence (O) Rank

Possible Failure Rates

≧1/2

＜1/3
＜1/8
＜1/20
＜1/80
＜1/400
＜1/2000
＜1/15000
＜1/150000
＜1/1500000

Reference Criteria; Detection (D) Rank

here is no known process control to detect the failure.
is very difficult to detect the failure by use of the current process control.
he failure is not detectable at the objective process, but very low chance operator-dependent process control such as visual inspection de
rocess.
ow chance operator-dependent process control such as visual inspection detects the failure at the objective process.
Moderately low chance the failure is detectable by use of gauges at the following process.
Moderately chance the failure is detectable by use of gauges at the objective process
igh chance the failure is detectable by automated process control at the following process.
igh chance the failure is detectable by automated process control at the objective process.
ery high chance the failure is detectable by automated process control while processing.
he robust process control certainly detects the failure. There is no chance to produce the failure.

R.P.N." = S x O x D.

ding to SQM.