GUJARAT FORGINGS Pvt Limited

Potential Failure Mode and Effects Analysis (Design) DFMEA No: DFMEA/GFL/DE00

Product: STARTING SYSTEM Prepared By:

Document Security Classification Approval: DFMEA Rev Date:
GFL confidential DFMEA ISSUE: ENG/CT/00

Team Members: Part Outline Drawing Rev:

Action Results

Resp. and

Class

RPN

RPN
Potential Effects of Potential Cause(s) / Current Design Controls Target

Occ

Occ
Sev

Det

Sev

Det
Ident Item / Function Potential Failure Mode Rec. Actions
Failure Mechanisms of Failure (P / D) Completion Actions Taken
Date

Engine to start in 1
1.1 Fails to start
pull

1.2

1.3

1.4

1.5

1.6

1.7

1.8

1.9

P = Prevention ; D = Detection
Page 1 of 12
Document Printed: 09/27/2021 09:25:34
 GUJARAT FORGINGS Pvt Limited
Potential Failure Mode and Effects Analysis (Design) DFMEA No: DFMEA/GFL/DE00

Product: STARTING SYSTEM Prepared By:

Document Security Classification Approval: DFMEA Rev Date:
GFL confidential DFMEA ISSUE: ENG/CT/00

Team Members: Part Outline Drawing Rev:

Action Results

Resp. and

Class

RPN

RPN
Potential Effects of Potential Cause(s) / Current Design Controls Target

Occ

Occ
Sev

Det

Sev

Det
Ident Item / Function Potential Failure Mode Rec. Actions
Failure Mechanisms of Failure (P / D) Completion Actions Taken
Date

1.10

1.11

1.12

1.13

1.14

1.15

1.16

1.17

1.18

P = Prevention ; D = Detection
Page 2 of 12
Document Printed: 09/27/2021 09:25:35
 GUJARAT FORGINGS Pvt Limited
Potential Failure Mode and Effects Analysis (Design) DFMEA No: DFMEA/GFL/DE00

Product: STARTING SYSTEM Prepared By:

Document Security Classification Approval: DFMEA Rev Date:
GFL confidential DFMEA ISSUE: ENG/CT/00

Team Members: Part Outline Drawing Rev:

Action Results

Resp. and

Class

RPN

RPN
Potential Effects of Potential Cause(s) / Current Design Controls Target

Occ

Occ
Sev

Det

Sev

Det
Ident Item / Function Potential Failure Mode Rec. Actions
Failure Mechanisms of Failure (P / D) Completion Actions Taken
Date

1.19

1.20

1.21

1.22

1.23

P = Prevention ; D = Detection
Page 3 of 12
Document Printed: 09/27/2021 09:25:35
 DFMEA_OCCURENCE- DETECTION-SEVERITY

DFMEA Occurrence Encoding

Likely
Possible
Rank Keyword Probability of Failure Product) Failure
Failure Rates
Rates
10 >/= 100,000 PPM >/= 1 in 10
Very High Extreme: Almost inevitable
9 50,000 PPM 1 in 20
8 20,000 PPM 1 in 50
High High: Situation frequently occurs
7 10,000 PPM 1 in 100
6 5000 PPM 1 in 200
5 Moderate Moderate: Situation occasionally occurs 2000 PPM 1 in 500
4 500 PPM 1 in 2000
3 100 PPM 1 in 10,000
Low Low: Situation relatively rare
2 10 PPM 1 in 100,000
1 Remote Remote: Situation unlikely </= 1 PPM < 1 in 1,000,000

DFMEA Detection Encoding

Rank Keyword GFL Guideline for DFMEA AIAG Guideline for DFMEA

Design Control will not and/or can not detect a

Almost
10 Undetectable until failure occurred after SOP potential cause/mechanism and subsequent
Impossible failure mode; or there is no Design Control.
Failure w/warning while the product is in operating mode Very remote chance the Design Control will
9 Very Remote in the field, but prior to a failure occurring; ie. warning detect a potential cause/mechanism and
light, abnormal noise; after SOP subsequent failure mode.

Remote chance the Design Control will detect a

Can be detected and corrected within downstream
8 Remote customer's manufacturing facility prior to SOP
potential cause/mechanism and subsequent
failure mode.

Can be detected and corrected prior to shipping out the Very low chance the Design Control will detect a
7 Very Low finished product; I.e. manufacturing end of line testing or potential cause/mechanism and subsequent
manufacturing process control after PPAP failure mode.

Can be detected and corrected in / after validation
6 Low testing prior to print release, but will require major design
changes
Can be detected and corrected in / after validation
5 Moderate testing prior to print release, but will require minor design
changes
Can be detected and corrected through verification
Moderately
4 testing prior to design release, but will require major
High design changes.
Can be detected and corrected through verification prior
3 High to design release, but will require minor design changes.
Can be detected and corrected prior to engineering
2 Very High prototype; I.e. math calculation, stackup analysis,
modeling and simulation
Low chance the Design Control will detect a
potential cause/mechanism and subsequent
failure mode.
Moderate chance the Design Control will detect
a potential cause/mechanism and subsequent
failure mode.
Moderately high chance the Design Control will
detect a potential cause/mechanism and
subsequent failure mode.
High chance the Design Control will detect a
potential cause/mechanism and subsequent
failure mode.
Very high chance the Design Control will detect
a potential cause/mechanism and subsequent
failure mode.

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 DFMEA_OCCURENCE- DETECTION-SEVERITY

Almost Design Control will almost certainly detect a

Is designed to eliminate possibility of product not
1 meeting requirements.
potential cause/mechanism and subsequent
Certain failure mode.

Page 5 of 12 09/27/2021
 DFMEA_OCCURENCE- DETECTION-SEVERITY

DFMEA Severity Encoding

Impact on Process Impact on Product
Severity
Rank AIAG GFL AIAG (A) Appearance (F) Function
Keywords

Hazardous-without-warning:
Very high severity ranking when
Hazardous - Potential for injury or harm to operating a potential failure mode affects Hazardous- without- warning: (F)
May endanger operator (machine or assembly) without
10 Without
warning.
personnel. Non-compliance with governmental safe vehicle operation and/or May involve safety, and/or
Warning regulations (spill of hazardous material, etc). involves noncompliance with noncompliance with regulatory issues.
government regulation without
warning.

Hazardous-with-warning: Very
high severity ranking when a
Missed shipment shutting down customer’s potential failure mode affects Hazardous -with- warning: (F) May
Hazardous - May endanger operator (machine or assembly) with
9 With Warning warning.
production line. Equipment/machines severely safe vehicle operation and/or involve safety, and/or noncompliance
damaged. involves noncompliance with with regulatory issues.
government regulation with
warning.

Extreme/Very High: System function

Equipment/machines down for a significant
100% of product may have to be scrapped, or vehicle / Very High: Vehicle/item lost (F) Can’t use the system, but no
period of time. Major financial impact. Internal
8 Very High item repaired in the repair department with a repair time
production down which may lead to delay or short
inoperable, with loss of primary safety or noncompliance with
greater than one hour. function. regulatory issues. Customer walk
shipment.
home.

Serious disruption to downstream operation, or

Product may have to be sorted and a portion (less than major operational impact, e.g. extensive rework, Significant/High: Customer
High: Vehicle/item operable, but
100%) scrapped, or vehicle / item repaired in the repair major scrap, significantly increased in inventory. Dissatisfaction (A&F) The failure
7 High
department with a repair time between a half-hour and a Defect caught in customer plant, Dealer
at reduced level of performance.
causes high degree of customer
Customer dissatisfied.
hour. repair/rework, Product returned, major disruption dissatisfaction on the part user.
spill occurs.

Page 6 of 12 09/27/2021
 DFMEA_OCCURENCE- DETECTION-SEVERITY

Moderate: Vehicle/item
A portion (less than 100%) of the product may have to
Major disruption to production line. Defect operable, but Moderate: (F) Partial system function
be scrapped with no sorting, or vehicle / item repaired in
6 Moderate
the repair department with a repair time less than a half-
caught at Final Assembly / Test. Major rework comfort/convenience item(s) is lost, but still can use it without safety
required or scrap. inoperable. Customer concern.
hour.
experiences discomfort.

Low: Vehicle/item operable, but

Moderately Significant: Customer
comfort/convenience item(s)
100% of product may have to be reworded, or vehicle / Minor disruption to production. Defect caught at Dissatisfaction (A&F) the user will
operable at reduced level of
5 Low item repaired off-line but does not go to repair Final Assembly Line. Light rework or scrap. May
performance. Customer
notice a negative impact as failure
department. cause minor damages to tooling. occurs; i.e. difficult to apply, difficult to
experiences some
use, discomfort, etc.
dissatisfaction.

Very Low: Fit & finish; squeak & Very Low: (F) Parts of the system
Failure may cause inconvenience to subsequent
The product may have to be sorted, with no scrap, and rattle item does not conform. operable at reduced performance,
4 Very Low
a portion (less than 100%) reworked.
operations, minor rework required. Defect passed
Defect noticed by most and/or gradual performance
to next process.
customers. degradation.

Minor: Fit & finish; squeak &

Failure detected at subsequent operation. May
A portion (less than 100%) of the product may have to rattle item does not conform. Minor: Nuisance, noticeable (F)
3 Minor
be reworked, with no scrap, on-line but out-of-station.
cause slight inconvenience to subsequent
Defect noticed by average Nuisance but likely negligible.
operation, minor rework required.
customer.

Minor: Fit & finish; squeak &

A portion (less than 100%) of the product may have to
2 Minor
be reworked, with no scrap, on-line but in-station.
Failure detected at local operation, may cause
slight inconvenience to operation, minor rework.
Minor: (A) The user will probably
rattle item does not conform.
Defect noticed by discriminating
notice only a minor negative impact on
the product.
customer.

Imperceptible: Not noticeable (F) The

consequence will not have any
Slight inconvenience to operation or operator, or no
1 None
effect.
No effect detected. None: No effect. perceptible impact on the performance
of the product (A) The user will not
notice the consequence.

Page 7 of 12 09/27/2021
 Spark Plug
Cy Head/Combustion
Chamber

Spark Plug Cap Carburettor

TI Governor Spring

Ignition Coil Stop Switch

Throttle Lever

STARTING
Flywheel magneto SYSTEM
(FUNCTIONAL
/ BLOCK
DIAGRAM)
Pulley

Tortional Force
Electricomagnetic Energy
Rope Pull Physical Contact
Thermal Energy
 Customer Usage
P-P Variation - Choke not pull Degradation over time
- TI Circuit - Rope pulling not done on compression -Excess carbon deposition in cy head, cy bore
-Ignition Coil design -Wrong type spark plug -Excess carbon on spark plug
-Wrong type TI -Excess carbon on valve seat
-Diesel Not drained
-Overload running for long time

Interaction with other system Environment

-Rope to pulley contact improper -Starting in extrme cold condition
-Cy haed leakage -Starting at very high altitude
-Carburetor overflow -Running in so much dusty enviornment

Ignition System

Input Error State

-Torque to pull Control Factors - No start
-Compression ratio -Lot of attempts of starting
-Fuel air ratio
-Spark Plug selection
-Ignition Coil selection
-Flywheel magnet magnetism