Fmea Synthesis: Name Function

FMEA SYNTHESIS S
D
R
Product: EINLEGER MAL C8 Part number : 38141501

Client : CLERPREM
Applicant: Name function
F.GHANMI QUALIT.DEV
Participants: W.NAAMAN
M.MAALAOUI
S.EL HASSINI
B.EL MAY
Moderator: Name function
Planning : Task provided date Date of completion Subject

Initialisation 03/02/2020 03/02/2020 Creation
Task1
Task 2
Review:
Evolution
Date Initial Evolution 1 Evolution 2 Evolution 3 Evolution 4 Evolution 5
Total No. of cases
IPR>80
%
1,2
1
0,8
0,6
0,4
0,2
0
IPR [0; 80[ IPR [81; 100[ IPR [101; 200[ IPR [201; 500[
Evolution 3 Evolution 5 Evolution 5
Observations :
Actions pour IPR > 80
Points ouverts :
F QLT 022.C - 21/08/2017 AMDEC

Definition for CS EINLEGER MAL C8
Mold N° : 20002
Special Features (Definition): characteristic of a product or parameter of a manufacturing process that
may affect safety, regulatory compliance, suitability for employment, function, product performance or
finishing operations Later on this product.
Types of Special Features: (Example for a car door)
Safety: No open when the vehicle rolls

Regulations: Material with character inflamabilité, no sharp edges visible
Employability, montabilité: Position hinges OK to montabilité Vehicle
Feature: Open / Close
Product Performance: SAR after 15,000 cycles
Operation of exterior finish: No fat can interfere with painting
Special Features: Type :
Features to look for:
Process : Stages Actors
Material reception
storage
out of stock
Production
storage / shipment
F QLT 022.C - 21/08/2017 AMDEC

Severity of Effect
According to : AIAG standard FMEA 4th Edition
F QLT 022.C - 21/08/2017 AMDEC

Frequency of Occurrence
F QLT 022.C - 21/08/2017 AMDEC

Detection by Current Control
F QLT 022.C - 21/08/2017 AMDEC

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FAILURE MODES AND EFFECTS ANALYSIS (FMEA PROCESS)
Conception Validation Conception Validation Production N° FMEA : 2022020 Nota : C.S. = Caractéristiques spéciales
Référence: 38 141 501 Index : 9 Prepared by: fida ghanmi

Description: EINLEGER MAL C8 Date FMEA (org.) 03/02/2020
Core Team: S.EL HASSINI-B.EL MAY - M.MAALAOUI-F.GHANMI Date FMEA : 03/02/2020 Date Revision:
I. P.
R.
Step Process Potential failure mode Potential effect of failure G. C. S. Potential Cause O. Means of production or control D. Corrective(s) Action(s) Responsible Action results
I. P. R.
< 80
O.
G.
D.
Exigences Failure mechanism Control detection Control occurrence Time Actions retenues
Disruption of the production

Material reference different than Verification of the order by the BL at
No satisfaction of the customer order line at the customer / 6 2 Command entered on EPR 3 36 6 2 3 36
order reception
delivery blocked
Quantity delivred less than the Verification of the order by the BL at
6 3 Command entered on EPR 2 36 6 3 2 36
order reception None
6 Delay in sending the command 3 Following by CBN Command entered on EPR 2 36 6 3 2 36
6 Delay in reception of the material 3 Following commands on ERP Command entered on EPR 3 54 6 3 3 54
Loss of traceability of Control approval at reception (Reception

Loss of traceability of raw materials 4 Bad identification of raw material 2 Monotoring N° Batch by ERP 3 24 4 2 3 24
finished product control plan)
10-1 Unidentified Material
Material Control approval at reception (Reception
4 >PA6 GF30 DURETHAN 2 Monotoring N° Batch by ERP 3 24 4 2 3 24
Receiving control plan) None
BKV30H2.0 901510<
Absence of raw material Control approval at reception (Reception Internal testing material + no reception
4 3 3 36 4 3 3 36
compliance control plan) without record of compliance
Control approval at reception (Reception Complaitn to the supplier (Chagment
4 Bag ripped 3 3 36 4 3 3 36
control plan) packaging )
Material flammability Risk of fire 9 Flammability out of specification 3 Flammability Certificates ACCORDING TO UL94 V0 2 54 None 9 3 2 54
Control approval at reception (Reception Internal testing material + no reception

Controled and prohibited substance Contaminated material 9 Material out of specification 3 2 54 None 9 3 2 54
control plan) without record of compliance
Unavailable material / supply Transport strike,Planning are not

Disruption of the production 6 2 Safety Stock ( 3 weeks ) . Monotoring quantity by ERP 3 36 None 6 2 3 36
disruptions met by the suppliers
Identification and/or internal

Loss of traceability of
traceability of the raw material is not 4 Absence of internal identification 3 Periodic Inventories Production management "GPAO" 3 36 4 3 3 36
finished product
respected None
4 Error of internal codification 3 Periodic Inventories Production management "GPAO" 3 36 4 3 3 36
Safety Stock wrong Disruption of production 4 Error of Bag Location 3 Periodic Inventories Production management "GPAO" 3 36 4 3 3 36
Bag production back stored in None

4 3 Periodic Inventories Production management "GPAO" 3 36 4 3 3 36
the wrong location
4 The not respect of the FIFO 3 Periodic Inventories Production management "GPAO" 2 24 4 3 2 24
10-2 Storage
non-conforming material (material Control approval at reception (Reception Complaitn to the supplier (Chagment
Disruption of the production 6 Bag ripped 2 3 36 6 2 3 36
contaminated) control plan) packaging )
None
Complaitn to the supplier (Chagment
6 Damaged packaging 2 Visual Contol 3 36 6 2 3 36
packaging )

Non-usable material (blocked) 6 No record of compliance 2 Periodic Inventories Contol at reception (reception control plan) 3 36 6 2 3 36
line at the customer,
Physicochemical property was Material conformity sheet (reception Internal testing material + no reception None
6 2 3 36 6 2 3 36
different than the technical control plan) without record of compliance
6 Warehouses Unsuitable 1 Warehouses covred of sunlight Warehouses covred of sunlight 1 6 6 1 1 6
6 F QLT 022.C - 21/08/2017 AMDEC

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POTENTIAL D
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I. P.
R.
Reference error Batch error 4 Error Internal management 3 Periodic Inventories + Production order automatic FIFO compliance on system 3 36 None 4 3 3 36
10-3 Material
provision
Failure FIFO Bad Logistic Managmenet 4 Error Inernal Mangement 3 Periodic Inventories Planning + order on system 3 36 None 4 3 3 36
Drying temperature above the residual moisture determination +

Degradation of mechanical properties Loss of functionality 6 2 startup checklist 5 60 None 6 2 5 60
standard , Hot Material Alarm on desiccator
Loss of functionality or Drying temperature below the residual moisture determination +

Moisture 6 2 startup checklist 5 60 6 2 5 60
defect appearance standard , " Cold raw material " Alarm on desiccator
Absorption of the humidity in residual moisture determination +

6 2 startup checklist 5 60 6 2 5 60
20 - 1 Drying the hopper when machine stop Alarm on dessicator
None
inversing the drying parameters
6 2 parameter checklist OF+ drying material sheet 5 60 6 2 5 60
fo two materials
6 Missing dryer 2 Production documentation & instruction startup checklist 5 60 6 2 5 60
Mold non functional (not suitable for Disruption of the production Correspondence between planning-OF-
6 Misidentification Molds 3 Folder for each mold 2 36 6 3 2 36
press) line mold (ref engraved)
Nozzle press not adapted to the Verification of nozzle diameter on file
6 4 Checklist startup 3 72 6 4 3 72
mold nozzle (Setting plan)
6 Hot Zones block unidentified 4 Production file (Map control equipment) Indentifcation of zones on data sheet 3 72 6 4 3 72
None
20 - 3
Security Bride in front of operator side or mentionned on cahier de charge
Tool setup 6 Bride of security not visible 4 3 72 6 4 3 72
in the top of the mold TPI(standard TPI ).
Checking the battery before each mentionned on cahier de charge TPI

6 Safety battery nonfunctional 4 3 72 6 4 3 72
Mounting (tools sheet) (standard TPI ).
6 Safety battery not connected 4 Checklisy startup 3 72 6 4 3 72
turntable machine Not set( setup

6 machine not suitable for the 4 visual control+ startup cheklist OF + parameter sheet 6 4
mold)
Dedicated program for each parts + Nr of

Wrong injection parameter / Handling Other injection parameter Surveillance parameter activated + Part
Bad parts produced 8 2 tool indicated in each program + 2 32 None 8 2 2 32
parameter chooses controled at startup
Parameter data sheet + startup checklist
Bad circuit connection (Anomaly Disruption of the production Water circuit connected autctrl reaction by disconnecting the
6 2 Setting plan and cooling plan sheet 2 24 6 2 2 24
during the mold mounting) line improperly circuit to ensure the smooth flow
Thermostat temperature non- None

20-4 Production 6 4 Dimensionnal control Setting plan 3 72 6 4 3 72
compliant with the standard
setup
6 Rotation direction of the pump 2 Alarm on peripheral Setting plan + Preventif maintenance 3 36 6 2 3 36
Malfunction of the peripherals autctrl reaction by disconnecting the

equipments (Problème de 6 Water level low 2 circuit to ensure the smooth flow + alarm Setting plan + Preventif maintenance 3 36 None 6 2 3 36
line
fonctionalité équipement) on thermostat
visual verification and flow rate

6 Pump failure 2 complaince of pipe standard 3 36 None 6 2 3 36
verifictaion .
7 F QLT 022.C - 21/08/2017 AMDEC

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POTENTIAL D
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I. P.
R.
Appearance problem (and

Material degradation 8 unsuitable Injection parameter 3 alarm on press + disk + frequency ctrl Respect of the setting plan 3 72 8 3 3 72
parts deterioration
Press dedicated. If chgt, use a tonnage at

Press not suitable (diameter least equivalent with process Validation .
8 2 Visual control 3 48 8 2 3 48
screw / barrel ) + meetring stoke compatible with screw
diameter
None
do not purge the machine after visual control + control plan+ Alarm on respect the setting plan :Purge after every
8 3 2 48 8 3 2 48
stoppage the machine stop of the machine
8 Deficient T ° equipment control 2 Alarms implemented on machines preventive maintenance 3 48 8 2 3 48
Control during prodution (visual +

non-assembly at the client / Dedicated programm for each mold +
Material lack 6 Worng program for injection 3 diemnsional)+ checking of parameter 3 54 6 3 3 54
appearence problem startup checklist ;
during production
alarm on press + frequency ctrl +

6 Cushion insufficient 3 Respect of the setting plan 4 72 6 3 4 72
components compared with standard
nozzle plugging by foreign body

alarm on press +frequency ctrl +
6 from the field (Contaminated 2 Respect of the setting plan 3 36 6 2 3 36
Material)
alarm on press + setting plan validated +

6 Brocken parts in the mold 3 frequency ctrl + components compared Respect of the setting plan 3 54 6 3 3 54
with standard
6 Nonexistent Events 2 Events done and validated during the design and the 1st Test 3 36 6 2 3 36
None
frequency ctrl + components compared

6 Events blocked 3 frequency clean up ( 3 time per 24 h ) . 4 72 6 3 4 72
with standard
6 Statup parts without holding 3 Dimensionnal control Dismess start parts after startup 3 54 6 3 3 54

6 Injection Speed too low 3 frequency ctrl + components compared Respect of the setting plan 3 54 6 3 3 54
with standard
6 injection gate too small 2 Injection gate done and validated during the design and tin first test of the tool 3 36 6 2 3 36
6 Nozzle diameter not suitable 2 alarm on press + setting plan valdiated Respect of the setting plan 3 36 6 2 3 36

non-assembly / appearence
Burrs 7 Holding pressure too low 3 components compared with standard + Respect of the setting plan 3 63 7 3 3 63
problem
Control Plan
Visual control of components and

7 Worn Parting line 3 Respect of the setting plan 3 63 7 3 3 63
comparison with standard
Visual control of components and

7 Parting line damaged 3 Respect of the setting plan 3 63 7 3 3 63
comparison with standard
Volume switching to higher than alarm on press + frequency ctrl +

7 3 Respect of the setting plan 3 63 7 3 3 63
the standard components compared with standard .
None

7 Injection speed too fast 3 Respect of the setting plan 3 63 7 3 3 63
components compared with standard .
Alarm on press ( T° Validated at first test

7 Material too hot 3 Startup checklist 3 63 7 3 3 63
).
8 F QLT 022.C - 21/08/2017 AMDEC

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POTENTIAL D
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Conception Validation Conception Validation Production N° FMEA : 2022020 None Nota : C.S. = Caractéristiques spéciales

I. P.
R.

7 Material too fluid 3 components compared with standard + Respect of the setting plan 3 63 7 3 3 63
Control Plan

7 Snacthing of the ejectors 3 Respect of the setting plan 3 63 7 3 3 63
components compared with standard .

non-assembly at the client / Cooling time less than the
sink Marks 5 3 frequency ctrl + components compared Respect of the setting plan 4 60 5 3 4 60
appearence problem standard
with standard

5 Material too fluid 3frequency ctrl + components compared Respect of the setting plan 3 45 5 3 3 45
with standard
5 Parts without holding pressure 3 Respect of the setting plan 3 45 5 3 3 45
with standard +Dismess start parts after None
startup
Mold temperature higher than the
5 3 frequency ctrl + components compared Respect of the setting plan 3 45 5 3 3 45
standard
with standard
5 Packaging not suitable 3 Packaging control plan Packaging Plan validated in PPAP . 3 45 5 3 3 45
20 - 5 / 30 / 40
Production alarm on press + Programm of setting Auto - DismIss start parts after every
5 Startup parts without holding 3 3 45 5 3 3 45
startup inejection . startup
Weld line / burns fragile parts 7 Injection speed too fast 3 frequency ctrl + components compared Respect of the setting plan 3 63 7 3 3 63
with standard
1st level cleaning of the tool (3 time per

7 Mold dirty 2 Visual check in parts 5 70 7 2 5 70
24h )
7 holding too strong 2 frequency ctrl + components compared Respect of the setting plan 3 42 7 2 3 42
with standard None
Respect Setting plan and injection
7 Mold too hot 2 startup checklist 4 56 7 2 4 56
parameters
7 Material too hot 2 frequency ctrl + components compared Respect of the setting plan 3 42 7 2 3 42
with standard
injection gate too small or bad

7 2 Validation of the gate dimension and position during the design and the 1st Test 3 42 7 2 3 42
location
Alarm on dryer and visual control,

Moisture streaks Appearence problem 7 Wet Material 3 Respect of the setting plan 3 63 7 3 3 63

7 Material degraded 3 frequency ctrl + components compared Respect of the setting plan 3 63 7 3 3 63
with standard

7 Material too hot 3 frequency ctrl + components compared Respect of the setting plan 3 63 7 3 3 63
with standard None

7 suck back very important 3 frequency ctrl + components compared Respect of the setting plan 3 63 7 3 3 63
with standard

7 Injection speed too fast 3 frequency ctrl + components compared Respect of the setting plan 3 63 7 3 3 63
with standard
7 Mold too cold 3 alarm on press + setting plan validated startup checklist 3 63 7 3 3 63
9 F QLT 022.C - 21/08/2017 AMDEC

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POTENTIAL D
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I. P.
R.

non-assembly at the client /
Broken parts 8 Broken parts in the mold 3 frequency ctrl + components compared startup checklist 3 72 8 3 3 72
appearence problem
with standard
8 Brittle material 2 Material validated by the customer 3 48 8 2 3 48
None
8 Packaging not suitable 2 Packaging plan Packaging validated in Initial samples 3 48 8 2 3 48
significant drop height on the Alarm on robot if part not taken to the
8 3 Robot manipulation 3 72 8 1 4 32
carpet carpet
8 gripper robot Unsuitable 3 design validation + Validation In Run and Rate 3 72 8 1 4 32

Ejector marks 5 Ejection speed too fast 3 frequency ctrl + components compared Respect of the setting plan 3 45 5 3 3 45
appearence problem
with standard

Cooling time less than the
5 2 frequency ctrl + components compared Respect of the setting plan 3 30 None 5 2 3 30
standard
with standard
Visual check in parts during production

5 The ejector are not properly fitted 2 + alarma on the machine (ejection stroke Ejector validated during first trials 6 60 5 2 6 60
)

Depression 5 Holding pressure below standard 2 frequency ctrl + components compared Respect of the setting plan 3 30 5 2 3 30
appearence problem
with standard
Alarm on machine ( Tol. T° +/- 10 °C for

5 Material too hot 2 Startup checklist 3 30 5 2 3 30
all zones ) .
None
5 Injection speed too fast 3 Respect of the setting plan 3 45 5 3 3 45
with standard + alram with pressure
sensor .
Injection gate badly located or

5 2 Validation during design 3 30 5 2 3 30
too small
Non and/or problem alarm on press + setting plan validated +

Startup checklist + repsect of the validated
snatching of the insert assembly at the client / 7 Holding pressure too high 2 frequency ctrl + components compared 4 56 7 2 4 56
setting .
functionnal problem with standard
None
Validated ejection and injection
Frequency control - visual checking of
7 Mold design 2 parameters + validation mold design + 4 56 7 2 4 56
the parts .
adjustment of mold during FOT
Non and/or problem

Deformation , Breackage parts 5 Packaging not suitable 3 Packaging plan + visual control Validation packaging (Initial samples ) 3 45 None 5 3 3 45
assembly at the client
Non and/or problem

5 Incorrect packaging 3 Packaging plan + Production order Validation packaging (Initial samples ) 3 45 None 5 3 3 45
Non and/or problem

50 - 60 5 Damaged packaging 3 Packaging plan+ Visal control Validation packaging (Initial samples ) 3 45 None 5 3 3 45
Packaging -
Labeling & Final
control Non and/or problem
5 Bad palletizing 3 Packaging plan + Visual control Validation packaging (Initial samples ) 2 30 None 5 3 2 30
streaks marks Aparence problem 9 Handling parts without gloves 3 follow instruction in the control range training range 2 54 None 9 3 2 54
5 bad palletizing 3 Packaging plan + Visual control Validation packaging (Initial samples ) 2 30 None 5 3 2 30
10 F QLT 022.C - 21/08/2017 AMDEC

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POTENTIAL D
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I. P.
R.
Human error Declaration with ERP System + periodic

Wrong reference received Parts delivery blocked 7 3 Labeling identification for box and palett 3 63 None 7 3 3 63
inventory
ERP systme management of the

70- Storage Wrong emplacement Delivery perturbation 6 Operator error 3 Warehouse emplacement identification 3 54 None 6 3 3 54
emplacement
Packagning instruction + handling qualified

Damaged box Parts delivery blocked 7 Non suitabble handling 2 Visual control 4 56 None 7 2 4 56
operator
delivery failure / Stop Human error

Wrong reference 5 3 Visual Control ERP (Entreprise Ressource Planning) 3 45 None 5 3 3 45
customer production chain
5 Loss of label 3 Label on pallet ( Visuel control ) . ERP (Entreprise Ressource Planning) 2 30 None 5 3 2 30
5 Wrong Identification 3 Visual Control ERP (Entreprise Ressource Planning) 2 30 None 5 3 2 30
80 Expedition Non repect of command deadline

Stop customer production
5 No reception of the command 3 Date preset with the client to send order + acknowledgment 1 15 None 5 3 1 15
chain
5 Order entry failure 3 Stamp on the order of the date of seizure entry commande on system ERP 3 45 None 5 3 3 45
5 Production not planned 3 Order accepted + Deadline ERP (Enterprise Resource Planning) 3 45 None 5 3 3 45
5 Error in stock 3 Periodic inventory 3 45 None 5 3 3 45
11 F QLT 022.C - 21/08/2017 AMDEC

Fmea Synthesis: Name Function

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FMEA SYNTHESIS S

Product: EINLEGER MAL C8 Part number : 38141501

Moderator: Name function

Planning : Task provided date Date of completion Subject

Evolution 3 Evolution 5 Evolution 5

F QLT 022.C - 21/08/2017 AMDEC

Safety: No open when the vehicle rolls

Special Features: Type :

Features to look for:

Process : Stages Actors

F QLT 022.C - 21/08/2017 AMDEC

According to : AIAG standard FMEA 4th Edition

F QLT 022.C - 21/08/2017 AMDEC

According to : AIAG standard FMEA 4th Edition

F QLT 022.C - 21/08/2017 AMDEC

According to : AIAG standard FMEA 4th Edition

F QLT 022.C - 21/08/2017 AMDEC

Référence: 38 141 501 Index : 9 Prepared by: fida ghanmi

Disruption of the production

6 Delay in sending the command 3 Following by CBN Command entered on EPR 2 36 6 3 2 36

Loss of traceability of Control approval at reception (Reception

Control approval at reception (Reception Internal testing material + no reception

Unavailable material / supply Transport strike,Planning are not

Identification and/or internal

4 Error of internal codification 3 Periodic Inventories Production management "GPAO" 3 36 4 3 3 36

Bag production back stored in None

Disruption of the production

6 Warehouses Unsuitable 1 Warehouses covred of sunlight Warehouses covred of sunlight 1 6 6 1 1 6

6 F QLT 022.C - 21/08/2017 AMDEC

Référence: 38 141 501 Index : 9 Prepared by: fida ghanmi

Drying temperature above the residual moisture determination +

Loss of functionality or Drying temperature below the residual moisture determination +

Absorption of the humidity in residual moisture determination +

6 Missing dryer 2 Production documentation & instruction startup checklist 5 60 6 2 5 60

Checking the battery before each mentionned on cahier de charge TPI

6 Safety battery not connected 4 Checklisy startup 3 72 6 4 3 72

turntable machine Not set( setup

Dedicated program for each parts + Nr of

Thermostat temperature non- None

Malfunction of the peripherals autctrl reaction by disconnecting the

visual verification and flow rate

7 F QLT 022.C - 21/08/2017 AMDEC

Référence: 38 141 501 Index : 9 Prepared by: fida ghanmi

Appearance problem (and

Press dedicated. If chgt, use a tonnage at

8 Deficient T ° equipment control 2 Alarms implemented on machines preventive maintenance 3 48 8 2 3 48

Control during prodution (visual +

alarm on press + frequency ctrl +

nozzle plugging by foreign body

alarm on press + setting plan validated +

frequency ctrl + components compared

alarm on press + setting plan validated +

alarm on press + frequency ctrl +

Visual control of components and

Visual control of components and

Volume switching to higher than alarm on press + frequency ctrl +

alarm on press + frequency ctrl +

Alarm on press ( T° Validated at first test

8 F QLT 022.C - 21/08/2017 AMDEC

Référence: 38 141 501 Index : 9 Prepared by: fida ghanmi

alarm on press + frequency ctrl +

alarm on press + frequency ctrl +