POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS

Page 1 of 4
FMEA Rev: 10/9/2017 Product Rev. Level: 2 Prepared by: Lauren Ritter
Item: KAUTEX Outer Shield P/N 1056329-002 Key Date: 10/20/2017 Process Responsibility: Lauren Ritter
Core Team: Lauren Ritter, Steve Mason, Hector Muela, Angelo Caponi, Jim Hubbard, Mark Murfitt FMEA Date (Orig): 10/9/2017

C O D Action Results
Process
l S c Current Process Current Process e R Responsibility &
Step Potential Effects of Potential Potential Cause(s) of Recommended
Requirement a e c Controls Controls t P Target Completion Action(s) Taken
Failure Mode Failure s Failure u e Action(s) Sev Occ Det RPN
v Prevention Detection N Date Completion Date
Function s r c
10 - SMC
Manufacture HS 3502 SMC See SMC Department PFMEA

20 - SMC
Storage See SMC Department PFMEA

30 - Move
Materials to Correct material
Wrong SMC Production Operator
Press presented to
moved to press
Heat transfer 7 Operator Error 2 Package Labeling
Signoff at Press
7 98
molding cell

40 - Molding of
Part

40.1 - Material
prep Molded Part per Charge not
Possible thin part.
Acceptance proper
Possible cracking
7 Operator Error 2 Work Instructions Visual 7 98
Criteria size/shape

Charge not Possible thin part. Material weighed 100% of

proper weight Possible cracking
7 Operator Error 2 Work Instructions
the time before molding
5 70
40.2 - Operator
Loads Charge Mechanical
Flow lines, knit Charge not loaded in
lines
properties may be 7
proper location
2 Work Instructions Visual 7 98
reduced.

40.3 - Mold Part

in Press Poor cosmetics but P-sheet; Training, Mold Operator Detection
SMC will meet Mold Temperatures set-up verification sheet, (Visual), Mold Tech Audit
Visual defects
physical property
4
incorrect.
3
1st piece inspection of temperature
7 84
requirements press Audit sheet

Press Closure Speed P-Sheet, Machine

4
Incorrect.
3
Controls
Mold Tech Audit setup 7 84
Incorrect Tonnage P-Sheet, Machine
Nonfil wrong dimensions 4
exerted.
3
Controls
Mold Tech Audit setup 7 84

Molded Surface Difficulty assembling Mold dimensions Mold profiles check

Profiles not met. parts
8
incorrect
2
during initial mold buy-off.
CMM Check 6 96

40.4 - Cure time Under cured part;

Incorrect cure Incorrect press Process Sheets; First Process Audits, Check
time: too short
blister; pops; SC 6
settings
2
piece inspection gage fixture
5 60
dimensional
40.5 - Check for
Molding Defects Defect free Crack(s) Scrapped part 7 Part stuck in mold 2
Mold release sprayed as
Visual 7 98
molding required

Incorrect charge Work instructions /

7
placement
2
Training
Visual 7 98
Incorrect charge Work instructions /
7
pattern
2
Training
Visual 7 98
7 Poor tool condition 2 Mold PM Visual 7 98
Improper handling /
7
placing in rack
2 Work instructions Visual 7 98
Incorrect charge 100% weight check
7
weight
2
during operation
Thickness Audit 5 70
 POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS
Page 2 of 4
FMEA Rev: 10/9/2017 Product Rev. Level: 2 Prepared by: Lauren Ritter
Item: KAUTEX Outer Shield P/N 1056329-002 Key Date: 10/20/2017 Process Responsibility: Lauren Ritter
Core Team: Lauren Ritter, Steve Mason, Hector Muela, Angelo Caponi, Jim Hubbard, Mark Murfitt FMEA Date (Orig): 10/9/2017

C O D Action Results
Process
l S c Current Process Current Process e R Responsibility &
Step Potential Effects of Potential Potential Cause(s) of Recommended
Requirement a e c Controls Controls t P Target Completion Action(s) Taken
Failure Mode Failure s Failure u e Action(s) Sev Occ Det RPN
v Prevention Detection N Date Completion Date
Function s r c
Incorrect charge Work instructions /
7
pattern
2
Training
Visual 7 98
Minimal charges cut
7 Dry material / exposed 2
ahead / Training
Visual 7 98
Wrong mold
7
temperature
2 Setup procedure Mold Tech Audit 5 70
Wrong slow close
7
speed
2 Setup procedure Mold Tech Audit 5 70
Part too thick Inability to properly
locate part in
secondary fixtures, 100% weight check
Reduced fastener 7 Wrong charge weight 2
during operation
Thickness Audit 5 70
grip range (secondary
ops)

7 Improper tonnage 2 Setup procedure Mold Tech Audit 5 70

7 Improper mold set 2 Setup procedure Mold Tech Audit 5 70
7 Improper shimming 2 Setup procedure Mold Tech Audit 5 70
Part too thin Structural integrity
100% weight check
(weakened, less 7 Wrong charge weight 2
during operation
Thickness Audit 5 70
durable part)
7 Improper tonnage 2 Setup procedure Mold Tech Audit 5 70
7 Improper mold set 2 Setup procedure Mold Tech Audit 5 70
7 Improper shimming 2 Setup procedure Mold Tech Audit 5 70
Fiber tear Poor edge quality 3 Worn shear edge 2 Mold PM Visual 7 42
3 Improper deflash 6 Best practice training Quality audits 5 90
Improper charge Work instructions /
3
placement
3
Training
Visual 7 63
Improper press
3
parameters
2 Setup procedure Mold Tech Audit 5 30
Press vacuum setup
Porosity Cosmetics 3 Air bubble in material 5
procedure
Gauge reading 6 90

High/low temp in Temp guage instrument,

Non-Fil dimensional 7
press set up
3 Press setup procedure
dimensional check fixture
4 84

Edges not trimmed/ Orbital sander, best

Flash Cosmetics 4
deflashed smoothly
3
practice training, Psheet
Visual inspection 7 84

Correct temp/cure Temp guage instrument,

Under Cure structural integrity 7
time
3 Press setup procedure
dimensional check fixture
4 84

Rich material, low Best practice training,

Resin Rich Brittle part edge 7
glass content
2
work instructions
Visual 7 98
50 - Move Part
to table Part is labeled Operator placed Work instructions /
Label part
incorrectly
Part unidentifiable 6
wrong label on part
2
Training
Visual 7 84
 POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS
Page 3 of 4
FMEA Rev: 10/9/2017 Product Rev. Level: 2 Prepared by: Lauren Ritter
Item: KAUTEX Outer Shield P/N 1056329-002 Key Date: 10/20/2017 Process Responsibility: Lauren Ritter
Core Team: Lauren Ritter, Steve Mason, Hector Muela, Angelo Caponi, Jim Hubbard, Mark Murfitt FMEA Date (Orig): 10/9/2017

C O D Action Results
Process
l S c Current Process Current Process e R Responsibility &
Step Potential Effects of Potential Potential Cause(s) of Recommended
Requirement a e c Controls Controls t P Target Completion Action(s) Taken
Failure Mode Failure s Failure u e Action(s) Sev Occ Det RPN
v Prevention Detection N Date Completion Date
Function s r c

Part missing Operator did not place Work instructions /

Label part
label
Part unidentifiable 4
label on part
3
Training
Visual 7 84

Correct barcode
50.2 - Correct Part is labeled Operator placed Work instructions /
part number
to scan and P-
incorrectly
Part unidentifiable 6
wrong label on part
2
Training
Visual 7 84
sheet

60 - Sand mold
byes. All Holes Possible fit issues at
Holes off Mold created
Present and in
location
assembly or 5
incorrectly
2 Design reviews, CMM 6 pieces 6 60
Proper Location customer.

Holes too big / Possible fit issues at Mold created

too small customer.
5
incorrectly
2 Design reviews, CMM 6 pieces 6 60
Additional post
assembly issue at Operator fails to sand Work instructions /
Part not sanded
customer
8
part
3
Training
Visual 7 ## processing check to Steve Mason 10/23/2017 8 3 5 120
verify holes
70 - Move part
to Deflash table Properly Improper deflash
Incomplete method - does not
to deflash deflashed
deflash
Sharp, jagged edges 7
remove enough
2 Training, P-sheet Visual 7 98
edges Edges
material

Improper deflash
Doesn't meet trim line
tolerance
7 method - removes too 1 Training, P-sheet Visual 7 49
much material

80 - Operator
Inspects Parts
Ready to Ship Defects not Appearance/ Training, P-sheet, Quality Operator detection
Part seen or repaired Function diminished
SC 7 Operator Error 2
Aids (Visual)
7 98

90 - Pack Part
for Shipment
Improper
Parts are not Parts are damaged Operator detection
Damaged
orientation/quant
during transit
6 Operator Error 2 P-sheet
(Visual)
7 84
ity packed

Parts are
Correct Operator detection
container
damaged during scrap 6 Operator Error 2 P-sheet
(Visual)
7 84
transit
 POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS
Page 4 of 4
FMEA Rev: 10/9/2017 Product Rev. Level: 2 Prepared by: Lauren Ritter
Item: KAUTEX Outer Shield P/N 1056329-002 Key Date: 10/20/2017 Process Responsibility: Lauren Ritter
Core Team: Lauren Ritter, Steve Mason, Hector Muela, Angelo Caponi, Jim Hubbard, Mark Murfitt FMEA Date (Orig): 10/9/2017

C O D Action Results
Process
l S c Current Process Current Process e R Responsibility &
Step Potential Effects of Potential Potential Cause(s) of Recommended
Requirement a e c Controls Controls t P Target Completion Action(s) Taken
Failure Mode Failure s Failure u e Action(s) Sev Occ Det RPN
v Prevention Detection N Date Completion Date
Function s r c

Short shipment/ Operator detection

Correct quantity
over shipment
Inventory variance 4 Operator Error 2 P-sheet
(Visual)
7 56

100 - Parts
Parts maintain Parts get dirty in
Moved to Not ready for Container not Operator detection
Shipping
quality and storage from
assembly
6
assembled correctly
2 P-sheet
(Visual)
7 84
cleanliness local dust

Correct shipping
customer
label with wrong label
inconvenience
4 Human error 3 training Visual 7 84
correct box

Scrap / rework / not

Part damage
shippable
5 Handling damage 2 Material handling training Visual 7 70
110 - Parts
Shipped to Parts are
Kautex received Parts are
Parts are not usable,
undamaged and damaged or SC 7 Improperly packed 2 Training, P-sheet Visual 7 98
line shortage
with correct quantity short
quantity

Revision History
Date Page(s) Previous Revision New Revision
10/9/2017 All Initial Submission