PFMEA New Format

PLANNING & PREPARATION (Step 1)
Company Name:
Plant Location:
Customer Name:
Model Year/Number:
STRUCTURE ANALYSIS (STEP 2)
1. Process item 3. Process

Activities to work
be executed /
System, Subsystem, Part 2. Process step element
tasks to be completed /
Station No. and Name of Focus
element or process characteristics to
Overall
Name line Operation
or cell
of Process orelement
station Technical
Influencers be4M type /
product specifications
achieved
or assemblyfor which analysis is Proces 5M+1E factors
results / These are candidates defines
for
being done how the output
Health & Safety causes (Dominent Sources of the process could fail
Electric motor assy line OP 10_ sintred bearing press inofOperator
Variation) to meet the functional
process Negative of these will be Failure
Material requirement or design
Effect Negative of these willintent
Press machine be (fit and function)
Refer colour codes to establish relationship causes
Grey cell are related one to one, Blue cells are related one to one, Pink coloured cell are related one to one ( from s
Vulcanisation Green hose loading Pick up specified
green hose as per
Bar code lable
Pick up specified
mandrel as per the
route card
Apply lubrication as
per method sheet
456-908
Sub Assembly of Timing OP-10A Operator

Tensioner Press Fitting Arm with Pulley
Material
Press machine
Mwthod
Timing Tensioner
Assembly Line
2
9
10
Pressing operation OP-10B Operator

Press Fitting Pivot Bushing in
Arm Sub-Assembly Material
Press machine
6
7
10
Caulking operation OP-20 Operator

Caulking of Pivot Tube &
Support Plate Material
Press machine
3
4
10
Caulking operation OP-30 Operator

Manaual Assembly & Caulking
Material
Press machine
1
8
9
10
Testing & Marking OP-40 Operator

Performance Testing &
Marking Material
Press machine
5
6
10
Inspection & Packaging OP-50 Operator

Visual Inspection & Packaging
Material
Press machine
2
3
10
FUNCTION ANALYSIS (STEP 3)
2. Function of the
o be executed / process step and product
e completed1. / Function of the process item char.
aracteristicsFunction
to of system, Sub system, Part element or Process
(Quantitative value is
d optional )
candidates defines
for Technical product
how the output
specifications /
ominent Sources
of the processProces
could results
fail
n) /
to meet
Your the(NP+AE):
Plant functional
Health & Safety Press in sintered bearing
requirement
Assy of shaft or
intodesign
pole housing assembly. to achieve axial position
f these willintent
be to(fit
Ship andNegative
Plant function)of these will be
(CE): in pole housing to max
Assy
e to one, Pink of motor
coloured into
arevehicle
failure
cell mode door
related gap function
one to one ( from structure to function, 0.05 mmto failure)
End User (FE):
Window raises and lowers
To give a specified shape and cure the rubber to attain the To meet desired shape of
material properties the hose
Your Plant (NP+AE): Pressing of Arm with Pulley. Arm Pressing with Pulley
to achieve the Pull out
Ship to Plant (CE): Assy of tensioner on engine. load >1500 N
End User (FE): Not applicable
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):

Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):

Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):

Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):

Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):

Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):

Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):

Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):

Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):

Subject:
PFMEA Origin Date:
PFMEA Rev. Date/ Rev No.: -
CFT :
FAILURE ANALYSIS (STEP 4)
Severity (S) of FE
3.Function of the process work
element and process Char. 2. Failure Mode (FM) of
1. Failure Effects (FE) the process step (Focus
"What is being done"
element)
(Quantitative value is optional )
Machine presses the sintered Your Plant (NP+AE): 9 Axial position of

bearing into the pole housing Clearance too small to assemble sintered bearing is not
until the defined axial position shaft without potential damage reached (Incomplete
o failure) Ship to Plant (CE): action)
Assy of motor to vehicle door
requires additional insertion force
or with potential damage
End User (FE):
Comfort closing time too long for
user
To load with out tearing / NP : Uncured hose 9
scratching / breaking the hose by
using lubrication AE : Does not conform to specififed Incorrect Mandrel
dimensions Dimensions
Leak Incorrect green hose

dimensions
CE : Routing concerns / fouling
Bulge
Burst
Leak
Product Reliability
( B10 weibull life)
Machine presess Arm into the Your Plant (NP+AE): Offset rejection
pulley untill butting position of sub assembly.
reach.
Ship to Plant (CE): Pulley may
disassemble from arm due less pull Arm pressing with
out load. 8 pulley load less then
1500N
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE): 6

Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):

Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):

Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):

Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):

Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):

Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):

Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):

Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):
Your Plant (NP+AE):
Ship to Plant (CE):
End User (FE):

PFMEA ID Number:
Process Responsibility:
Confidentialilty Level:
EP 4) RISK ANALYSIS (STEP 5)
Occurrence (O) of
Detection (D) of
Characteristic
PFMEA AP
Current
Special
FC/FM
3. Failure Cause (FC) of Current Prevention Detection Prevention
FC
the work element Control (PC) of FC Controls (DC) Action
of FM or FC
Machine stops before Proximity sensor 6 Use of 9

reaching the final position Go/NoGo
Gauge
H
incorrect mandrel picked
up for loading
1-Less travel of ram

1.PLC controlled
2-Alignment of arm and
2.Fixture design
pulley is not as per the
requirement
controlled 3 9 M
3.Fixture
3.Part resting face of
revalidation
fixture worn out
6 4 M
OPTIMIZATION (STEP 6)
Occurrence (O)
Detection (D)
SpProd Char
Severity (S)
PFMEA AP
Detection Resp. Person Target Action taken Completion
Completion Status with pointer
Action Name
date of evidence date
Remarks
What if Failure
Not meeetig the intended funtion(s)
e.g Wall clock

Failures - symptoms
Shows less time (actual se kam)
Shows more time ( actual > real time)
stop
Funtion of wall clock To provide accurate time
Structure Hands, Gears, Spring , Wooden bezel, Glass cover + pendulam
Input Process
Spring force _> Kinetic Energy Gear wheels Rotation
spring force less Coil spring lower torque -> slow gear wheels rotation -> Slower hand movement -> In accur
Stops early
Spring coil (no of coils ) less
Failure effect
Failure mode
Failure cause
Control of failure cause
Wooden bezel, Glass cover + pendulam
Output
Time needles rotate as per the speed / gear ratio
ar wheels rotation -> Slower hand movement -> In accurate time ( less time)

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PLANNING & PREPARATION (Step 1)

STRUCTURE ANALYSIS (STEP 2)

1. Process item 3. Process

Sub Assembly of Timing OP-10A Operator

Pressing operation OP-10B Operator

Caulking operation OP-20 Operator

Caulking operation OP-30 Operator

Testing & Marking OP-40 Operator

Inspection & Packaging OP-50 Operator

End User (FE): Not applicable

Your Plant (NP+AE):

Ship to Plant (CE):

End User (FE):

Ship to Plant (CE):

End User (FE):

Your Plant (NP+AE):

Ship to Plant (CE):

End User (FE):

Your Plant (NP+AE):

Ship to Plant (CE):

End User (FE):

Your Plant (NP+AE):

Ship to Plant (CE):

End User (FE):

Your Plant (NP+AE):

Ship to Plant (CE):

End User (FE):

Your Plant (NP+AE):

Ship to Plant (CE):

End User (FE):

Your Plant (NP+AE):

Ship to Plant (CE):

End User (FE):

Your Plant (NP+AE):

Ship to Plant (CE):

End User (FE):

Ship to Plant (CE):

End User (FE):

Your Plant (NP+AE):

Ship to Plant (CE):

End User (FE):

Your Plant (NP+AE):

Ship to Plant (CE):

End User (FE):

Your Plant (NP+AE):

Ship to Plant (CE):

End User (FE):

Your Plant (NP+AE):

Ship to Plant (CE):

End User (FE):

Your Plant (NP+AE):

Ship to Plant (CE):

End User (FE):

Your Plant (NP+AE):

Ship to Plant (CE):

End User (FE):

Your Plant (NP+AE):