POTENTIAL FMEA #:

FAILURE MODE AND EFFECTS ANALYSIS Reference Specs:

(PROCESS FMEA)
Item/Component: Process Responsibility: Prepared by:

Model: Part Number: Date (Orig.)

CoreTeam: Date (last revised)

Approved by:

The Sev and RPN columns auto-calculate.

DETECT
OCCUR
Action Results

CLASS

RPN
SEV
Process Function/ Potential Effect(s) of Potential Cause(s)/ Current Process Controls Current Process Controls Responsibility & Target
# Potential Failure Mode Recommended Actions S O D R.
Requirements Failure Mechanism(s) of Failure Prevention Detection Completion Date
Actions Taken e c e P.
v c t N.
Nut not properly tighten 3 1 1 3 3 0
Missing rubber isoletor 3 1 1 3 3 0
rubber collar not outside the
compressor base plate
3 1 1 3 3 0

Base plate with Thread problem 1 1 1 1 1 0

1
compressor assembly
base plate not proper paint 1 1 1 1 1 0
grounding wire not use in
compressor
2 1 1 2 2 0

Stud missalign 1 1 1 1 1 0

not properly tighten screws 3 3 2 18 3 0

capillary chip & crack 3 1 1 3 3 0

Service valve and capillary Lnkey nut thread slip
2 5 2 1 10 5 0
fix on valve plate
lock of valve plate fixing miss 1 1 1 1 1 0

copper tube damages 4 1 1 4 4 0

condenser fins broken & damage 2 2 1 4 2 0

copper tubes damage & chip 3 2 1 6 3 0

Condenser fix on base
3 ubend leakage & chip 3 1 1 3 3 0
plate
Condenser fixing hole block &
miss
1 1 1 1 1 0

not properly tighten screws 2 1 1 2 2 0

4-way valve & solenoid coil are
not same brand
2 1 1 2 2 0

tubes damage & chip 3 2 1 6 3 0

4-way valve damage 2 1 1 2 2 0

4-way valve fixing &
4
copper tubes fitment all tubes & capillary fixing not
2 1 1 2 2 0
properly

all tubes & capillary missalign 1 1 1 1 1 0

Solenoid coil screw loose 1 1 1 1 1 0

not proper welding 3 1 1 3 3 0

nitrogen pressure not inside the

5 Welding copper tube
1 1 1 1 1 0

leakage problem 2 1 1 2 2 0

motor nut not properly tighten 2 1 1 2 2 0

bracket screws not properly
tighten
2 1 1 2 2 0
Pre-assemble motor fixing
6 & motor bracket fixing on motor wire clip damage 2 1 1 2 2 0
base plate
bracket clip of wire fixing not use 1 1 1 1 1 0

motor body damage 1 1 1 1 1 0

wiring not properly against

wiring diagram
3 1 1 3 3 0

wire damage 1 1 1 1 1 0

Compressor wiring & gasket miss of terminal cover 2 1 1 2 2 0

7
blanket fixing
terminal cover nut not properly
tighten
2 1 1 2 2 0

blanket not proper rapping on

compressor
1 1 1 1 1 0

Partation plate screws not

properly tighten
2 1 1 2 2 0

Spoung miss 1 1 1 1 1 0

partation plate fix on base grove 1 1 1 1 1 0

fixing partation plate &
8
PFC / Capacitor PFC/Capacitor fixing screws not
properly tighten
2 1 1 2 2 0

PFC damage 2 1 1 2 2 0

Service and art pipe coupler not

proper fix 1 1 1 1 1 0

not proper vacuuming 3 1 1 3 3 0

Coupler not proper fix 1 1 1 1 1 0

wiring not properly against
wiring diagram
3 1 1 3 3 0

wire clip damage 1 1 1 1 1 0

PCB damage 2 1 1 2 2 0
Vacuuming, wiring &
9 PCB cover not properly fix 1 1 1 1 1 0
axial fan fixing
all sensor not properly fix 1 1 1 1 1 0

all wires not properly tie 1 1 1 1 1 0

PCB parts damage 2 1 1 2 2 0

axial fan damage 1 1 1 1 1 0

axial fan fixing nut not properly
tighten
2 1 1 2 2 0

dumper not proper paste on

capillary tube
1 1 0 0 1 0

refrigerant not proper fill against

gas weight sheet
3 1 1 3 3 0

The machine charged the leak

unit
3 1 1 3 3 0
Refrigerant filling &
10
Pinch off Gas weight not verification 2 1 0 0 2 0

Pinch pillar not proper pinch 2 1 1 2 2 0

Gas leakage 2 1 1 2 2 0

Welding not properly pinch off 1 1 0 0 1 0

machine working not properly 3 2 1 6 3 0

machine not calibrate 2 1 1 2 2 0

Leak check with Inficon
11
machine Untrained inspector work in leak
check station
2 1 0 0 2 0

Inspector check unit very fast 2 1 0 0 2 0

not properly tighten screws 2 1 1 2 2 0

PCB box damage 1 1 0 0 1 0

Right side plate, PCB box, not proper screw use in 1 1 0 0 1 0

12 Ground wire & Front panel grounding wire
fixing
Electric terminal broken 1 1 0 0 1 0

ground wire screw not properly

tighten
2 1 1 2 2 0

Earth wire not proper work 5 2 1 10 5 0

Insulation resistance test not ok 5 2 1 10 5 0

13 Electrical safety test
wiring problem 3 1 1 3 3 0

Electrical Safety test not ok 5 2 1 10 5 0

testing panel not check before

unit testing
3 1 1 3 3 0

Heating process not check 3 1 1 3 3 0

Current (A) not proper check
against given supplier 3 1 1 3 3 0
specification sheet
Online testing
14 Running pressure not proper
(Performance test) check against given supplier 2 1 1 2 2 0
specification sheet

Inverter PCB not check properly

with supplier device
4 1 1 4 4 0

Power not proper check against

given suppler specification sheet
2 1 1 2 2 0

valve cap not fix & miss 1 1 1 1 1 0

Remove coupler, fix valve diagram sticker miss 2 1 1 2 2 0
cap, diagram paste on
right side handle, rating rating label sticker miss 1 1 1 1 1 0
15 label paste on right side
plate, right side handle fix water collector broken 1 1 1 1 1 0
on eclectic plate & water
collector fixing right side handle broken 1 1 1 1 1 0

Power cable fixing clip miss 1 1 1 1 1 0

not proper cleaning 1 1 1 1 1 0

Cleaning, Packing
installation kit miss 2 1 1 2 2 0
(Polythen bag, installation
17
kit, hole cover & pvc roll polythen bag miss 1 1 1 1 1 0
tape
hole cover & pvc tape miss 1 1 1 1 1 0

carton damage & broken 1 1 1 1 1 0

Packing carton
18 & EPS top miss 1 1 1 1 1 0
Packing strip
packing strip loose 1 1 1 1 1 0

Carton reopen not properly 1 1 1 1 1 0

Dismantling & unit reopen not properly 1 1 1 1 1 0
1
Parts segregation
unit damage to the dismantling
process
2 1 1 2 2 0

3 1 1 3 3 0
not properly screw tighten

2 1 1 2 2 0
cross flow fan broken
Cross flow fan & indoor 2 1 1 2 2 0
2
motor assemble motor shaft tapper

2 1 1 2 2 0
motor wire damage

2 1 1 2 2 0
bearing base not proper place

evaporator fins damage 2 2 1 4 2 0

copper tubes damage & chip 2 1 1 2 2 0

ubend damage & chip 2 1 1 2 2 0

heat exchanger pipe damage &

chip 2 1 1 2 2 0
3 Evaporator fixing
not properly screws tighten 2 2 1 4 2 0

motor cover not proper fix 2 1 1 2 2 0

cover screw not properly tighten 2 1 1 2 2 0

evaporator not properly fix 2 1 1 2 2 0

not properly screw tighten 2 1 1 2 2 0

PCB box damage 1 1 1 1 1 0

PCB with box & ground
4
wire fixing PCB component damage 3 2 1 6 3 0
ground wire not properly screw
tighten
2 1 1 2 2 0
Power cord wire not properly
tighten
2 1 1 2 2 0
terminal broken 2 1 1 2 2 0
Indoor motor wire jack not fix in
the PCB
2 1 1 2 2 0
5 Wiring swing motor wire jack not fix the
PCB
2 1 1 2 2 0
Air & Coil sensor wire jack not fix
the PCB
2 1 1 2 2 0
Coil sensor not fix in evaporator
coil
2 1 1 2 2 0

Enclosure not properly fix 2 1 1 2 2 0

top panel not properly fix 1 1 1 1 1 0
Enclosure & Top panel,
6 filter miss 2 1 1 2 2 0
Filter & Louver flap
not properly screw tighten 2 1 1 2 2 0
louver flap miss & broken 2 1 1 2 2 0

Remote function not check

properly
4 2 1 8 4 0

Inverter PCB not check properly

Online Indoor Testing with supplier device
4 2 1 8 4 0
7
(Performance Test)
louver moment not check 2 1 1 2 2 0

unit vibration not properly check 2 1 1 2 2 0

Hanging plate miss 3 1 1 3 3 0

wrong hanging plate dispatch 2 1 1 2 2 0
Hanging plate &
8 hanging plate damage 2 1 1 2 2 0
Terminal cover
terminal cover not fix 1 1 1 1 1 0
terminal cover broken 1 1 1 1 1 0

not proper cleaning 1 1 1 1 1 0

Cleaning & Packing Power cable miss 1 1 1 1 1 0

9 (Polythen bag & Power
Cable) polythen bag miss 1 1 1 1 1 0

Scratches 1 1 1 1 1 0

Packing carton carton damage & broken 1 1 1 1 1 0

10 &
Packing strip packing strip loose 1 1 1 1 1 0

BE-PDP-FR-07 / Rev D (14-Nov-13) Johnson Controls, Inc. Page 1 of 1

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