Failure Mode and Effects Analysis (Process Fmea) : Potential

POTENTIAL
FAILURE MODE AND EFFECTS ANALYSIS

Edition: 1 Revision: 3 (PROCESS FMEA) FMEA Number: 01.18.AM
Part name/No. : PLASTIC PANEL BACK ASM 1R AE LH / RH Process Responsibility: Bodiu I Prepared by: Mihai Alexandru
Drawing no.: 4106586 REV. AG
Prodcut Line Key Date Date (Orig.) 19.03.2018
Core Team: Blanaru V, Bodiu I , Mihai A, Moldovan A Date (Rev.) : 03.09.2021
C O Current D
Process Potential c Process e R. Responsibility Action Results
Function/
Potential Potential S l
Causes(s)/ Recommended & Target
Failure Effect(s) e a c Controls t P. S O D R.
Require- Mechanism(s) u -Prevention e N. Action(s) Completion Actions e c e P.
ments
Mode of Failure v s of Failure Date Taken
s r -Detection c v c t N.
1.0 Issue order part Subscription check full data
2.0 Suplly
2.1 Inventory/Establish what wrong wrong elaboration 6 personal 4 supervision 3 72
materials is needed / inventory suplly order inattention inventory
elaboration orders
6 out of warranty 3 each delivery check as 3 54
2.2 Check supply material nonconforming material Rejection material Work instr. IL-11
6 damaged on transport 3 check loading in truck; 3 54
the proper fitting of the
materials in the truck by the
carrier
6 non-compliant quantity 3 non-compliance by the 3 54

with order vendor of the order
2.3 Stored material in improper stored damages of materials 6 failure to comply Work Instr. 4 check storage as Work 3 72
warehouse by operator Instruction
3.0 Release material for release improper nonconforming part 7 improper respect specific 3 release materials with 3 63
production material of work instructions FIFO method
POTENTIAL
Part name/No. : PLASTIC PANEL BACK ASM 1R AE LH / RH Process Responsibility: Bodiu I Prepared by: Mihai Alexandru
Core Team: Blanaru V, Bodiu I , Mihai A, Moldovan A Date (Rev.) : 03.09.2021
C O Current D
Function/
ments
Pag. 1/8
POTENTIAL
Part name/No. : PLASTIC PANEL BACK ASM 1R AE LH / RH Process Responsibility: Padureanu J Prepared by: Mihai Alexandru
Core Team: Blanaru V, Padureanu J, Mihai A, Moldovan A Date (Rev.) 03.09.2021
C O Current D
Function/
ments
4.0 Cutting carbon fiber
4.1 Prepare material improper conditioning improper cutting 5 not respecting conditions 4 check conditions of prepa- 3 60
prior to use materials from technical data sheet ring/conditioning materials
4.2 Cutting carbon Manual improper cutting material reboot or use at 6 operator error at marking 4 visual check 3 72
fiber other products after pattern or cutting training operator
6 wrong pattern 4 check periodically pattern 3 72
Improper cutting on material reboot or use at 6 Improper fastening material 4 check fixing material before 4 96
Cutter Plotter other products on the machine table of cutting
failure function of vacuum check periodically vacuum
pump/not watertight seating pump/seating surface of
surface cutter plotter
6 Used cutting knife 4 Preventive mainten. 4 96

6 defective function of 3 check function cutter 3 54
assembly traverse/cutting plotter before cutting material
knife support/transmission preventive maintenance
belts
POTENTIAL
C O Current D
Function/
ments
Pag. 2/8
POTENTIAL
C O Current D
Function/
ments
5.0 Lay up inner Improper active surface nonconforming part 6 not respecting work instr. 4 visual check mould/ 4 96
of mould by operator (at preparing preventive mantenance
part (impurities, dust, low of mould for lamination/at training operators
6.0 Lay up outer gloss, porosities, scratch, begenning of operation)
part aparent point
of resin)
Fiber wrong direction scrap part 8 failure to comply 3 check direction as per 3 72
on visible surface plybook plybook/training operators
zone with Improper nonconforming part 7 layup improper 3 check on flow of laminate 5 105
adhesion between layers training operators
7 contamination of surface 3 check surface materials 5 105

materials check cleaning of work
area/mode keeping materi-
als
7 improper vacuum bag 3 check vacuum bag 5 105

Deformation of the fiber 6 4 visual check 4 96
nonconforming part layup improper
(tensioned fiber/zone training operators
with folds of material)
6 defective material 4 check material before of 4 96
applying
Inclusions of particles 6 not conform preparation 4 check preparation of the 4 96
in a part surface: dust, nonconforming part of the mould mould/preventive menten.
fluffs, remains of fibres 6 not conform check material 4 check material before of 4 96
hair yarns before lamination lamination/training operators
6 not conform work equip- 4 wearing suitable work 4 96
ment operator equipment
6 not conform cleaning in 4 permanent keeping a clean 4 96
workshop workshop
excessive overlapping weight over admissible 6 not conform cutting of ma- 4 check cut materials 3 72
of materials limit/nonconforming part terials, did not meet the check layup process
requirements work instr. training operators
POTENTIAL
C O Current D
Function/
ments
insuficent overlaping weight under admissible 8 not conform cutting of ma- 3 check cut materials 3 72
of materials limit/scrap part terials, did not meet the check layup process
requirements work instr. training operators
7.0 Drying/curing - in Inadequate dried nonconforming part 8 accidental fault (at heating 3 check drying parameters on 2 48
autoclave: system, recirculating heat curing cycle
_inner part air by electric fan, vacuum preventive maintenance
_outer part pump, not watertight on
vacuum bag, pressuring
system)
8 interruption electric power 3 Connection electric generator 2 48

reserve
POTENTIAL
C O Current D
Function/
ments
8.0 Lay up zone with improper nonconforming part 7 improper lay up 3 check lay up process 5 105
compression film, adhesion between layers training of operators
airex C71,
assembling inner 7 improper vacuum bag 3 check vacuum bag 5 105
part with outer part training ofoperators
inadequate joint line in the nonconforming part 6 areas with excessive 4 check weight of adhesive 4 96
area of cuts, after adhesive on the mold surface check uniformity layer
assembling the internal adhesive
and external mold training of operators
6 improper cutting of material 4 check operation 3 72

on perimeter of moulds, training operators
before asssembling
6 improper clamping of flange, 4 check assembling operation 4 96

between int. and ext. mold training of operators
9.0 Drying/curing - in Inadequate dried nonconforming part 8 accidental fault (at heating 3 Check drying parameters 2 48
autoclave, system, recirculating heat preventive maintenance
assembling inner air by electric fan, vacuum
with outer part pump, not watertight on
vacuum bag, pressuring
system)
8 interruption electric power 3 Connection electric generator 2 48

reserve
10. Demoulding Part damaging / nonconforming part/scrap 8 Not suitable extractors 4 Check extractors/replacem. 3 96
Part breaking 8 Improper treatment with 4 Check treatment mold 3 96
release agent training operators
8 improper technique of 4 check operation 3 96
operator training operators
POTENTIAL
C O Current D
Function/
ments
Preparing mould for active surface with nonconforming aspect of 5 used mould/nonconforming 4 preventive maintenance 3 60
a new cycle porosities, skratch, zone part maintenance/improper check preparing mould
with low gloss, points in technique of operator training operators
relief with resin
uneven application of damaged of mould/part 7 improper technique of 3 check operation 4 84

release agent operator/not respecting training operators
work instruction
Pag. 4/8
POTENTIAL
Part name/No. : PLASTIC PANEL BACK ASM 1R AE LH / RH Process Responsibility: Roman D / Padureanu J Prepared by: Mihai Alexandru
Core Team: Blanaru V, Padureanu J, Mihai A, Molovan A Date (Rev.) 03.09.2021
C O Current D
Function/
ments
11. 1st off evaluation exccesive weight of nonconforming part 6 bigger cutting materials 4 check cut materials 3 72
(after demoulding part big overlap materials check layup process
part) improper technique operator training operator
inssuficient weight of nonconforming part/scrap 8 imprper cutting of materials 3 check cut materials 3 72
part improper laminating check layup process
training operator
damaged part scrap part 8 improper treatment mould 4 check treatment mould 3 96
(after demoulding) with release agent training operators
8 Not suitable extractors 4 Check extractors/replacem. 3 96
8 improper demoulding per- 4 check mode demoulding 3 96

formed by operator check/ training perators
inadequate joint line in the nonconforming part 6 areas with excessive 4 check weight of adhesive 4 96
area of cuts, after adhesive on the mold surface check uniformity layer
6 improper cutting of material 4 check operation 3 72

on perimeter of mould training operators

Improper external aspect - defects in carbon fiber layer

excessive porosities Nonconforming part 6 improper material 4 check material 4 96
6 improper surface of mould 5 check preparing mould 4 120 Increase prevent. Permanent/
maintenance of acc. with
mould after evidence of
max.12 pieces lamin. parts
Padureanu J
6 improper vacuum bag 4 Check vacuum pressure 4 96

Distorsion of fiber/ Nonconforming part 6 Improper laminating 3 Check operations of laminat. 4 72
tissue ,training operators
POTENTIAL
C O Current D
Function/
ments
fluff/broken fibre nonconforming part 6 improper material 4 check material before lamina- 5 120 Check annual Man A.
tion visual accuracy of 12.2019
operator
acumulation of resin nonconforming part 6 prepreg with excessive 3 check supply materials 4 72
resin
6 improper vacuum bag 4 check preasure vaccum 4 96
training operator
maintenance of vacuum hoses
and couplings
black dots nonconforming part 6 improper material 4 check material before lamina- 5 120 Check annual Man A.
tion visual accuracy of 12.2019
operator
Inclusions of particles nonconforming part 6 improper lamination 4 check preparation of 4 96

(dust, fluffs, hair yarns) (preparation of mould, check mould/preventive mainten.
of materials before lay up, Check materials
cleaning of workshop, check cleaning workshop
equipment of operators) check work equipment of
operators
Wrong direction fiber on scrap part 8 Improper laminating 3 Check fiber direction 3 72
visible surface training operator
scratches nonconforming part 6 improper surface of mould 4 check preparing mould 5 120 Increase prevent. Permanent/
maintenance of acc. with
mould after evidence of
max.12 pieces lamin. parts
Padureanu J
6 improper demoulding 4 Check operations of laminat. 4 96

,training operators
6 improper handling 4 check mode transport and 4 96

handling/training operators
POTENTIAL
C O Current D
Function/
ments
zone with delaminations nonconforming part 7 contamination between 3 check cleaning work shop 5 105
between layers (air bubble layers (inadequate cleaning check work equipment of
under layer of the work area / of the operators
working equipment ) check mode keeping of
materials
7 improper lamination / 3 Check operations of laminat. 5 105

vacuuming ,training operators
Verify vacuum bag
Labeling
improper labeling nonconforming part 5 inattention operator 4 visual check 4 80
(missing label/improper relabeling training operators
positioned/improper
date completed)
Pag.5/8
POTENTIAL
Part name/No. : PLASTIC PANEL BACK ASM 1R AE LH / RH Process Responsibility: Muresan V / Flueras A Prepared by: Mihai Alexandru
Core Team: Blanaru V, Flueras A, Moldovan, Mihai A. Date (Rev.) 03.09.2021
C O Current D
Function/
ments
Product Machining
12. Outline cutting, Improper cutting from Nonconforming part 6 Failure cutting program 3 Program check machine 4 72
decoupage dimensional point of scrap/rework 6 Worn milling tool 4 Check/Replace tool 4 96
drilling holes for inserts
view 6 Impproper fixing in device 4 Check fixing part 4 96
zone on cutting edge with nonconforming part 6 worm milling tool 4 Check/Replace tool 3 72
fringe material or scrap/rework 6 improper speed tool 3 check/change speed tool 4 72
broken
6 improper lamination 4 check layup process 4 96
training of operators
zone of perimeter cutting nonconforming part 7 improper lamination 3 check layup process 4 84
edge with delamination training of operators
improper holes from Nonconforming part 6 Failure drilling program 4 Program check machine 3 72
dimensional point of scrap/rework 6 Worn milling tool 4 Check/Replace tool 3 72
view (diameter/position)
6 Impproper fixing in device 4 Check fixing part 3 72
improper aspect edge of nonconforming part 6 worm milling tool 4 Check/Replace tool 4 96
holes (with fringe scrap/rework 6 improper speed tool 4 check/change speed tool 4 96
material or broken)
zone edge of hole nonconforming part 7 improper lamination 3 check layup process 5 105
with delamination training of operators
13. Montage inserts Improper aspect Nonconforming part 6 Worker skill/not respecting 4 Visual check 4 96
montage: excessive rework work instruction Training worker
adhesive, scratches on
visible surface of inserts,
sharp edges, burrs from
machining, scratches
from tracing
thread with impurities nonconforming part 6 not respecting work instr. 4 Visual check 4 96
rework training operator
improper thread / holes nonconforming part 7 thread/holes with drying 3 check each thread with 4 84
scrap/rework adhesive after mounting inserts control screw
Check diameter of holes
improper distance nonconforming part 7 improper operation of gluing 4 check operation 4 112 Mounting jig for Grad D
between inserts Training of operatoe bushings 30.11.2018
7 improper drilling 3 check machining program/ 4 84

fixing in device/milling tool
POTENTIAL
C O Current D
Function/
ments
the bushing glued in the nonconforming part 7 inattention of operator 4 check bucshing with position 4 112 Update mounting Grad D
wrong area from drawing jig for new 30.12.2018
bushings
14. Lacquering
14.1 Preparing surface traces from grinding/ Nonconforming part 6 improper grinding 4 visual check 4 96
for varnishing scratches, excessive abrasive disk with large cleaning/replace disk
grinding-damaged granulation or unclean training operators
aspect of texture mater.
inclusions of abrasive nonconforming part 6 improper clean surface 4 Check cleaning surface 4 96
particles, dust
inadequate joint line, in nonconforming part 6 not respecting work instr. 4 Visual check 4 96
zone of assembling Training of operator
between internal and
external part
scratches from tracing, for nonconf. Part/rework 6

preparing zone for gluing Visual check tracing with Grad D
not respecting work instr. 4 3 96
of inserts nonconf. Part/scrap 8 Training of operator protective discs 30.11.2018
varnish layer with 6 improper preparing/spraying 4 check preparing/sprayng 4 96

14.2 Lacquering of varnishing materials training operators
craters nonconforming part
blistering of solvent nonconforming part 6 small time for evaporation 4 check time evaporation, as 4 96
between layers per data sheet
too thick layer reduction thickness layer
area with leaking of nonconforming part 6 _ improper diameter/angle 4 check respect spraying 4 96
varnish nozzle spraying gun parameters from technical
_bigger spraying preassure data sheet of materials
_skill of operator training operators
_delayed gelling
impurities in layer nonconforming part 6 working area with impurities 6 periodically maintenance 5 180 Increase Flueras A
unclean fixing device for spray booth/fixing device frequency of 30.12.2018
spraying cleaning
6 improper transfer between the 6 check transfer of part 5 180 Protection of parts Flueras A
area of preparation and in boxes/bags 30.12.2018
painting
improper adherence nonconforming part 7 improper drying 3 check drying parameters 4 84
7 contamination of surface 3 Check cleaning surface 4 84

7 improper preparing of 3 check mode preparing 4 84
varnishing materials materials before spraying
POTENTIAL
C O Current D
Function/
ments
different color of layer, nonconforming part 6 over drying 4 check time of drying 4 96
after drying
6 improper time of flash of 4 check time of flash of, 4 96
training of operator
14.3 Drying Improper drying Nonconforming part 6 malfunction heating system 3 Check heating system. 3 63
(sticky layer) carrying out preventive
maintenance
6 small time/temperature of 3 check drying parameters 3 63
drying as per technical data sheet
Pag. 6/8
POTENTIAL
S
E C
R. Responsibilty& Action Results
V l
Process Potential Effects of Potential causes/Mechanism Recommended Target
OCC
S
DET
Potential Failure Mode a Current Procces Control P. S D R.
Step/Function Failure E of Failure -Preventions N. Actions Completion
Actions taken E E P.
OCC
s Date
V
s -Detections V T N.
15. Final Check
weight over admissible Nonconforming part / 6 bigger cutting layers/over- 4 check cut materials 3 72
Check weight part limit scrap laping materials check layup process
improper technique of oper. training operator
weight under admissible nonconforming part 8 improper cutting materials/ 3 check cut materials 3 72
limit scrap not respecting work instr. check layup process
training operator
porosity nonconforming part 6 improper surface mould 5 check preparing mould 4 120 Increase prevent. Permanent/
Check maintenance of acc. with
internal/external mould after max.12 evidence of
aspect of carbon pieces lamin. parts
fiber layer Padureanu J
6 improper cured in autocla- 4 periodically check vacuum 4 96

-ve/improper vacuum bag circuits on cycle
preventive maintenance of
vacuumm system
6 prepreg with excessive 4 check supply materials 4 96

resin
Fiber/texture deformed nonconforming part 6 Improper laminating 3 Check operations lamination 4 72
training operators
fluff/broken fibre nonconforming part 6 improper material 4 check material before 5 120 Check annual visual Man A.
lamination accuracy of operator 12.2019
acumulation of resin nonconforming part 6 prepreg with excessive 3 check supply materials 4 72
resin
fiber layer
POTENTIAL
S
E C
V l
OCC
S
DET
Step/Function acumulation of resin Failurepart
nonconforming E of Failure -Preventions N. Actions Completion
OCC
s Date
V
6 improper vacuum bag 4 check preasure vaccum 4 96
training operator
maintenance of vacuum
hoses and vacuum couplings
black dots nonconforming part 6 improper material 4 check material before 5 120 Check annual visual Man A.
lamination accuracy of operator 12.2019
Inclusions of particles nonconforming part 6 improper lamination 4 check preparation of 4 96

(dust, fluffs, hair yarns) (preparation of mould, check mould/preventive mainten.
of materials before lay up, Check materials
cleaning of workshop, check cleaning workshop
equipment of operators) check work equipment of
operators
Wrong direction fiber Nonconforming parts/ 8 Improper laminating 3 Check fiber direction with 3 72
scrap pattern
training operator
scratches nonconforming part 6 improper surface of mould 4 check preparing mould 5 120 Increase prevent. Permanent/
check mould before before the maintenance of acc. with
lamination begins mould after max.12 evidence of
pieces lamin. parts
Padureanu J
6 improper demoulding 4 Check operations of 4 96
demoulding,training operators
6 improper handling 4 check mode transport and 4 96

handling/training operators
zone with delaminations nonconforming part 7 contamination between 3 check cleaning work shop 5 105
between layers (air bubble layers (inadequate cleaning of check work equipment of
under layer) the work area / of the working operators
equipment ) check mode keeping of
materials
POTENTIAL
zone with delaminations nonconforming part S
between layers (air bubble E C
under layer) V l
OCC
S
DET
OCC
s Date
V
7 improper lamination / 3 Check operations of laminat. 5 105
vacuuming ,training operators
Verify vacuum bag
inadequate joint line in the nonconforming part 6 areas with excessive adhesive 4 check weight of adhesive 4 96
area of cuts, after on the mold surface check uniformity layer
6 improper cutting of material on 4 check operation 3 72

perimeter of mould training operators

zone with improper nonconforming part 6 improper lamination 4 Check operations of laminat. 4 96
lamination (material with Use help tools, in hardly
fold or tensioned, accesible areas
in special in hardly training operators
accesible areas
Improper cutting from Nonconforming part 6 Failure cutting program 3 Program check machine 4 72
Cutting, drilling dimensional point of scrap/rework 6 Worn milling tool 4 Check/Replace tool 4 96
part
view 6 Impproper fixing in device 4 Check fixing part 4 96
zone on cutting edge with nonconforming part 6 worm milling tool 4 Check/Replace tool 3 72
fringe material or scrap/rework 6 improper speed tool 3 check/change speed tool 4 72
broken
zone of cutting edge nonconforming part 7 improper lamination 3 check layup process 4 84
with delamination training of operators
unfinished zone on nonconforming part 5 not respecting work instr. 4 Visual check 4 80
edge rework by operator training operators
Improper aspect Nonconforming part 6 Worker skill/not respecting 4 Visual check 4 96

Mounting special
bushings
POTENTIAL
S
E C
V l
OCC
S
DET
OCC
s Date
V
Mounting special montage: excessive rework work instruction Training worker
bushings adhesive, scratches on
visible surface of inserts,
sharp edges, burrs from
machining, scratches from
tracing
thread with impurities nonconforming part 6 not respecting work instr. 4 Visual check 4 96
rework training operator
improper thread/diameter nonconforming part 7 thread/hole with drying 3 check each thread with 4 84
of holes scrap/rework adhesive after mounting control screw
inserts check diameter of holes
improper distance nonconforming part 7 improper operation of gluing 4 check operation 4 112 Mounting jig for Grad D
between inserts Training of operator bushings 30.11.2018
7 improper drilling 3 check machining program/ 4 84
fixing in device/milling tool
the bushing glued in the nonconforming part 7 inattention of operator 4 check bucshing with position 4 112 Update mounting jig Grad D
wrong area from drawing for new bushings 30.12.2018
varnish layer with nonconforming part 6 improper preparing/spraying 4 check preparing/spraying 4 96

Check varnishing craters of varnishing materials training operators
surface
blistering of solvent nonconforming part 6 small time for evaporation 4 check time evaporation, as 4 96
between layers per data sheet
too thick layer reduction thickness layer
area with leaking of nonconforming part 6 _ improper diameter/angle 4 check respect spraying 4 96
varnish nozzle spraying gun parameters from technical
_bigger spraying preassure data sheet of materials
_skill of operator training operators
_delayed gelling
impurities in layer nonconforming part 6 working area with impurities 6 periodically maintenance 5 180 Increase frequency Flueras A
unclean fixing device for spray booth/fixing device of cleaning 30.12.2018
spraying
POTENTIAL
Check varnishing FAILURE MODE AND EFFECTS ANALYSIS
surface
S
E C
V l
Process Potential Effects
part of Potential causes/Mechanism Recommended Target
OCC
impurities S
PotentialinFailure
layer Mode nonconforming
DET
a Current Procces Control P. S D R.
OCC
s Date
V
6 improper transfer between the 6 check transfer of part 5 180 Protection of parts in Flueras A
area of preparation and boxes/bags 30.12.2018
painting
scratches in varnish nonconforming part 6 improper seating part on 4 check seating zone of part 4 96
layer flow production on flow production
improper handling training mode handling
fingerprint on varnish nonconforming part 6 handling part before proper 4 check drying part 3 72
surface drying
improper adherence nonconforming part 7 improper drying 3 check drying parameters 4 84
7 contamination of surface 3 Check cleaning surface 4 84
7 improper preparing of 3 check mode preparing 4 84

varnishing materials materials before spraying
Improper gloss nonconforming part 6 skill of worker 4 Visual check/training oper. 3 72

rework 6 improper materials 4 check materials 4 96
different color of layer, nonconforming part 6 over drying 4 check time of drying 4 96
after drying 6 improper time of flash of 4 check time of flash of, training 4 96
of operator
Improper dimensions Nonconforming part 7 Control instruments with 3 Regular check 3 63

Dimensions reject / reworking measuring errors control instruments
7 Improper machining 3 4 84
product because of :
_ improper fixing part in check machining devices
machining device /mentenance
_ used tool check tool/replace
_ worker skill/not respecting training operators
Work Instruction
Improper labeling / Nonconforming part / 5 Not respecting Work Instr. by 4 Visual check 4 80
Check labeling part absence label / wrong relabeling operator Training operator
positioned / improper
completion
POTENTIAL
S
E C
V l
OCC
S
DET
OCC
s Date
V
Page 7/8
POTENTIAL
Part name/No. : PLASTIC PANEL BACK ASM 1R AE LH / RH Process Responsibility: Muresan V Prepared by: Mihai Alexandru
Core Team: Blanaru V, Flueras A, Moldovan A, Mihai A. Date (Rev.) 03.09.2021
C O Current D
Function/
ments
16. Package Improper product pro- Nonconforming part 6 Worker skill / Not respecting 4 Check packaging /Training 3 72
tection; deterioration of the work instruction worker
surface
Improper labeling 6 4 3 72
Improper closure box 6 4 3 72
17. Storage final Incorrect storage Nonconforming part 6 Worker skill / Not res- 3 Check storage 3 54
parts Improper handling 6 pecting work instruction 4 Training worker 3 72
18. Transport final parts to the customer
18.1 Generate Incorrect completion Not respecting customer 6 inattention personnel 3 Check delivery docu- 4 72
delivery order ment with customer
documentation
order and stock parts.
18.2 Loading Improper handling Nonconforming part 6 inattention personnel 4 Check loading truck 3 72
Incorrect loading number/ Not respecting customer 6 Incorrect delivery doc. 3 Check delivery doc. 3 54
type of products order 6 innatention personnel 4 Check loading truck 3 72
18.3 Transport Improper binding parts Nonconforming part 6 carrier has not complied with 4 Check loading truck 4 96
during of transport the safety measures for the
transport of goods
POTENTIAL
Part name/No. : PLASTIC PANEL BACK ASM 1R AE LH / RH Process Responsibility: Muresan V Prepared by: Mihai Alexandru
Core Team: Blanaru V, Flueras A, Moldovan A, Mihai A. Date (Rev.) 03.09.2021
C O Current D
Function/
ments
Pag. 8/8
ISSUE CHANGE RECORD – PFMEA
Part name / No.: BACKSHELL AE471
ISSUE LEVEL NAME DESCRIPTION OF CHANGE REASON FOR CHANGE DATE AUTHORISED BY
Ed. 1 / Rev. 0 Mihai A Elaborated 19.03.2018 Blanaru V

Ed. 1 / Rev. 1 Mihai A Revised number of severity, occurance 16.07.2018 Blanaru V
and detective class, acc. Document
Daimler received from Recaro.
Ed. 1 / Rev. 2 Mihai A update failure page 4- assembling mold, observations after PV 19.11.2018 Blanaru V
page 5-check after demoulding
update failure page 6,7 mounting inserts
preparing surface, check external surf.
Ed. 1 / 3 Mihai A Change rev. of drawing new rev. drawing - AC 1/25/2019 Blanaru V
Ed. 1 / 4 Mihai A Revised number of severity, occurance 2/12/2019
and detective class
Change rev. of drawing Change rev. of drawing- AD 8/5/2019
Ed. 1 / 5 Change rev. of drawing Change rev. of drawing- AF
ICR - rev.1 / Aug. 2010

Failure Mode and Effects Analysis (Process Fmea) : Potential

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POTENTIAL

FAILURE MODE AND EFFECTS ANALYSIS

6 non-compliant quantity 3 non-compliance by the 3 54

6 Used cutting knife 4 Preventive mainten. 4 96

7 contamination of surface 3 check surface materials 5 105

7 improper vacuum bag 3 check vacuum bag 5 105

8 interruption electric power 3 Connection electric generator 2 48

6 improper cutting of material 4 check operation 3 72

6 improper clamping of flange, 4 check assembling operation 4 96

8 interruption electric power 3 Connection electric generator 2 48

uneven application of damaged of mould/part 7 improper technique of 3 check operation 4 84

8 improper demoulding per- 4 check mode demoulding 3 96

6 improper cutting of material 4 check operation 3 72

6 improper clamping of flange, 4 check assembling operation 4 96

Improper external aspect - defects in carbon fiber layer

6 improper vacuum bag 4 Check vacuum pressure 4 96

Inclusions of particles nonconforming part 6 improper lamination 4 check preparation of 4 96

6 improper demoulding 4 Check operations of laminat. 4 96

6 improper handling 4 check mode transport and 4 96

7 improper lamination / 3 Check operations of laminat. 5 105

7 improper drilling 3 check machining program/ 4 84

scratches from tracing, for nonconf. Part/rework 6

varnish layer with 6 improper preparing/spraying 4 check preparing/sprayng 4 96

improper adherence nonconforming part 7 improper drying 3 check drying parameters 4 84

7 contamination of surface 3 Check cleaning surface 4 84

6 improper cured in autocla- 4 periodically check vacuum 4 96

6 prepreg with excessive 4 check supply materials 4 96

Inclusions of particles nonconforming part 6 improper lamination 4 check preparation of 4 96

6 improper handling 4 check mode transport and 4 96

6 improper cutting of material on 4 check operation 3 72

6 improper clamping of flange, 4 check assembling operation 4 96

Improper aspect Nonconforming part 6 Worker skill/not respecting 4 Visual check 4 96

varnish layer with nonconforming part 6 improper preparing/spraying 4 check preparing/spraying 4 96

improper adherence nonconforming part 7 improper drying 3 check drying parameters 4 84

7 contamination of surface 3 Check cleaning surface 4 84

7 improper preparing of 3 check mode preparing 4 84

Improper gloss nonconforming part 6 skill of worker 4 Visual check/training oper. 3 72

Improper dimensions Nonconforming part 7 Control instruments with 3 Regular check 3 63

Ed. 1 / Rev. 0 Mihai A Elaborated 19.03.2018 Blanaru V

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