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C

L
Item / Potential Causes/
Potential Failure Mode Potential Effects of Failure SEV A OCC
Function Mechanisms of failure
S
S

NHA - No signal at hardware assemly S Load cell enclosure 5


stage/ Loss of priamary function 8 C design incorrect

Water entry due to


S poor design 5
Customer - No Effect as of now but need to C
be captured (it is loss of primary function if 1 (8) Other instractions
it gets captured) related causes need to
adressed
End user - Warning detection function fails, S 5
No detection of the load loss of primary function. 8 C

Safety and Regulatory - C


loss of lives & loss of property without 10 C
warning,
Load
Detector/ C
Correct Legal :
detection Legal Action: loss of revenue & reputation. 10 C
of load

Sometimes showing
values
malfunctioning over the
period
Results variation is lesser
than tolerance

Showing values without


event or excessive values
of small events
Current Design Current Design
Recommended Responsibility & target DFMEA Action results
controls controls DET DFMEA AP
action completion date

Prevention Detection Actions taken SEV OCC DET DFMEA AP


Item / Function Potential Failure Mode Potential Effects of Failure SEV C
L
A
S
S
I
F
Correct detection of No detection / reflection NHA - No signal at hardware assembly stage/ Loss 8 I
of the load of priamary function C
load at the time of
event A
Customer - No Effect as of now but need to be 1 (8) T
captured (it is loss of primary function if it gets
captured) I
O
End user - Warning detection function fails, loss of 8 N
primary function.

Safety and Regulatory - 10


loss of lives & loss of property without warning,

Legal : 10
Legal Action: loss of revenue & reputation.

Showing inconsistant NHA - Fluctuation of value at hardware assemly 8


values stage/ Loss of priamary function

Customer –will get alert over email or SMS about 8


system as well as pysically on site there will be
indication.

End user - Warning detection function partially 10


fails, loss of primary function.

Safety and Regulatory - 10


loss of lives & loss of property without warning,

Legal : 10
Legal Action: loss of revenue & reputation.

Incorrect values / NHA - incorrect value at hardware assemly stage/ 10


malfunctioning over the Loss of priamary function
period
Customer -No Effect as of now but need to be 10
captured

End user - may get incorrect values and false 10


trigger of the system.Or event may not captured,
loss of primary function.

Safety and Regulatory - 10


loss of lives & loss of property without warning,

Legal : 10
Legal Action: loss of revenue & reputation.
Results variation is lesser NHA – inaccurate trigger of event at hardware 8
than tolerance assemly stage/ Loss of primary function

Customer - No Effect as of now but need to be 8


captured

End user - may get incorrect trigger of an event to 8


the system.Or event may not captured , loss of
primary function.

Safety and Regulatory - 10


loss of lives & loss of property without warning,

Legal : 10
Legal Action: loss of revenue & reputation.

Showing values without NHA – No trigger of event at hardware assemly 10


event or excessive values stage/ Loss of primary function
of small events
Customer - No Effect as of now but need to be 10
captured

End user – may not get trigger of an event to the 10


system.Or event may not captured, loss of primary
function.

Safety and Regulatory - 10


loss of lives & loss of property without warning,

Legal : 10
Legal Action: loss of revenue & reputation.

Realtime No communication NHA –No communication at hardware assemly 10


communication of stage/ Loss of primary function
values to server
Customer –will get alert over email or SMS about 9
system as well as pysically on site there will be
indication.

End user – Warning detection function fails, loss of 10


primary function.
Safety and Regulatory - 10
loss of lives & loss of property without warning,

Legal : 10
Legal Action: loss of revenue & reputation.

Intermittent NHA – Interrupted communication at hardware 10


communication due to assemly stage/ Loss of primary function
situation like rain and
sunlight,
Customer – will get alert over email or SMS about 8
system as well as pysically on site there will be
indication.

End user – Warning detection function fails, loss of 10


primary function.
Safety and Regulatory - 10
loss of lives & loss of property without warning,
Legal : 10
Legal Action: loss of revenue & reputation.

delay in communication NHA –No communication at the right time or no 7


over the period realtime event captured at hardware assemly
stage/ Loss of primary function

Customer – will get alert over email or SMS about 10


system as well as pysically on site there will be
indication.

End user – Warning detection function fails, loss of 10


primary function.

Safety and Regulatory - 10


loss of lives & loss of property without warning,

Legal : 10
Legal Action: loss of revenue & reputation.

Fluctuations in NHA –No communication at the right time or no 10


communication realtime event captured at hardware assemly
stage/ Loss of primary function

Customer – will get alert over email or SMS about 10


system as well as pysically on site there will be
indication.

End user – Warning detection function fails, loss of 10


primary function.
Safety and Regulatory - 10
loss of lives & loss of property without warning,

Legal : 10
Legal Action: loss of revenue & reputation.

Load data for No change in the load NHA –No event will be generated if there is any at 8
immediate event hardware assemly stage/ Loss of primary function
as well as
cumulative load is
provided Customer – No Effect as of now but need to be 8
captured (it is loss of primary function if it gets
captured)

End user – Warning detection function fails, loss of 8


primary function.
Safety and Regulatory - 10
loss of lives & loss of property without warning,

Legal : 10
Legal Action: loss of revenue & reputation.

Sometimes values is NHA –No right event will be generated if there is 8


geting updated any at hardware assemly stage/ Loss of primary
function.
sometimes not.
Customer – will get alert over email or SMS about 8
system as well as pysically on site there will be
indication.

End user – Warning detection function fails, loss of 10


primary function.
Safety and Regulatory - 10
loss of lives & loss of property without warning,

Legal : 10
Legal Action: loss of revenue & reputation.

getting values lesser NHA –No event or event savirity will not be 8
than actual load generated at hardware assemly stage/ Loss of
primary function.

Customer - No Effect as of now but need to be 10


captured (it is loss of primary function if it gets
captured)

End user – Warning detection function fails, loss of 10


primary function.
Safety and Regulatory - 10
loss of lives & loss of property without warning,

Legal : 10
Legal Action: loss of revenue & reputation.

there may loss in the NHA - No signal at hardware assemly stage/ Loss of 10
data packets in between priamary function
due to wireless network
Customer – will get alert over email or SMS about 10
system as well as pysically on site there will be
indication.

End user – Warning detection function fails, loss of 10


primary function.
Safety and Regulatory - 10
loss of lives & loss of property without warning,

Legal : 10
Legal Action: loss of revenue & reputation.

showing values NHA – False trigger of an event at hardware 10


expectedly high or low assemly stage/ Loss of priamary function
than expected without
any event.
Customer – will get alert over email or SMS about 10
system as well as pysically on site there will be
indication.

End user – Warning detection function fails, loss of 10


primary function.

Safety and Regulatory - 10


loss of lives & loss of property without warning,

Legal : 10
Legal Action: loss of revenue & reputation.

If there is an certain load is detected NHA – Lack of trigger of an event at hardware 10


anomaly, it must but no alerts triggered assemly stage/ Loss of priamary function
be easy to detect
Customer – No Effect as of now but need to be 10
captured (it is loss of primary function if it gets
captured)
be easy to detect

End user – Warning detection function fails, loss of 10


primary function.

Safety and Regulatory - 10


loss of lives & loss of property without warning,

Legal : 10
Legal Action: loss of revenue & reputation.

sometimes certain load NHA – Inconsistant reporting of an event at 10


is detected sometimes hardware assemly stage/ Loss of priamary function
actual load is detected
Customer – will get alert over email or SMS about 8
system as well as pysically on site there will be
indication.

End user – Warning detection function fails, loss of 10


primary function.

Safety and Regulatory - 10


loss of lives & loss of property without warning,

Legal : 10
Legal Action: loss of revenue & reputation.

Battery backup No battery power NHA – No power to the device at hardware 10


and robustness received assemly stage/ Loss of priamary function
should servive
device for long
backup. Customer – will get alert over email or SMS about 10
system as well as pysically on site there will be
indication.

End user – Warning detection function fails, loss of 10


primary function.

Safety and Regulatory - 10


loss of lives & loss of property without warning,

Legal : 10
Legal Action: loss of revenue & reputation.

Battery powered NHA – Signal will not be received or incomplete 10


insufficient current, information at hardware assemly stage/ Loss of
priamary function
causes some function to
work and some not.
Customer – will get alert over email or SMS about 10
system as well as pysically on site there will be
indication.

End user – Warning detection function fails, loss of 10


primary function.
Safety and Regulatory - 10
loss of lives & loss of property without warning,

Legal : 10
Legal Action: loss of revenue & reputation.

Battery is giving backup NHA – Insufficient Power to the hardware assemly 8


lesser than exptected stage/ Loss of priamary function
Battery is giving backup
lesser than exptected

Customer : will get alert over email or SMS about 8


system as well as pysically on site there will be
indication.

End user – Warning detection function fails, loss of 8


primary function.

Safety and Regulatory - 10


loss of lives & loss of property without warning,

Legal : 10
Legal Action: loss of revenue & reputation.

Battery is providing NHA – Higher current spur at hardware assembly 2


higher current than stage / No loss of primary function.
expected or battery is
giving higher backup
than expected. Customer: 2

End user – No effect on live detection function, No 2


loss of primary function.

Safety and Regulatory - 2

Legal : 2
Legal Action:

Battery is not constantly NHA – Signal will not be received or incomplete 10


providing current, it information at hardware assemly stage/ Loss of
priamary function
varies continously.
Customer – will get alert over email or SMS about 10
system as well as pysically on site there will be
indication.

End user – Warning detection function fails, loss of 10


primary function.
Safety and Regulatory - loss of lives & loss of 10
property without warning
Legal : Legal Action: loss of revenue & reputation. 10

Device should be Damaged enclouser due NHA – Ingress Damage at hardware assemly stage/ 10
water / humidity / to heavy object falls on it Loss of priamary function
damage proof / damaaged due to
and should be water / humidity entry. It Customer: will get alert over email or SMS about 10
easy to carry and has not handle to carry system as well as pysically on site there will be
indication.
installation..
End user – Warning detection function fails, loss of 10
primary function.

Safety and Regulatory - loss of lives & loss of 10


property without warning
Legal : Legal Action: loss of revenue & reputation. 10

Device Damage or Theft NHA – Signal will not be received or incomplete 10


information at hardware assemly stage/ Loss of
priamary function
Device Damage or Theft

Customer: will get alert over email or SMS about 10


system as well as pysically on site there will be
indication.

End user – Warning detection function fails, loss of 10


primary function.

Safety and Regulatory - loss of lives & loss of 10


property without warning

Legal : Legal Action: loss of revenue & reputation. 10

Due to damage, it may NHA – Signal will not be received or incomplete 10


happen some functions information at hardware assemly stage/ Loss of
priamary function
may work due to cut in
wiring.
Customer: will get alert over email or SMS about 10
system as well as pysically on site there will be
indication.

End user – Warning detection function fails, loss of 10


primary function.
Safety and Regulatory - loss of lives & loss of 10
property without warning
Legal : Legal Action: loss of revenue & reputation. 10

Device should No hole for anchor NHA – Cannot fit / install to system, No signal / 10
pass anchor rod function at hardware assemly stage/ Loss of
priamary function
all the way
accross through
device hole. Customer: It is captured. 10
End user – 10
Safety and Regulatory - 10
Legal : Legal Action: 10

hole is present but given NHA – Cannot fit / install properly to system, No 8
diameter are inaccurate. signal / function at hardware assemly stage/ Loss
of priamary function

Customer: It is captured. 8
End user – 8
Safety and Regulatory - 8
Legal : Legal Action: 8

hole is present but NHA – Cannot fit / install properly to system, No 8


diameter is less than signal / function at hardware assemly stage/ Loss
of priamary function
expected.
Customer: It is captured. 8
End user – 8
Safety and Regulatory - 8
Legal : Legal Action: 8
Easy for Very hard to maintaince. NHA – Difficult Maintenance process. 8
mantainance. Everytime need to take
device down and open
for any mantainance is
time and money Customer: will get alert over email or SMS about 8
investing. maintainance of system as well as pysically on site
there will be indication.

End user – loss of primary function during 8


maintanance.
Safety and Regulatory - loss of lives & loss of 10
property without warning
Legal : Legal Action: loss of revenue & reputation. 10

Previously maintainance NHA – Repeated Maintenance Difficult 8


was easy but now due to
some reason it is difficult
to make the
maintanance. Customer: will get alert over email or SMS about 8
maintainance of system as well as pysically on site
there will be indication.

End user – loss of primary function during 8


maintanance.
Safety and Regulatory - loss of lives & loss of 10
property without warning
Legal : Legal Action: loss of revenue & reputation. 10
Potential Causes/ Mechanisms of failure OCC Current Design Current Design DET DFMEA Recommende Responsibility & target
controls controls AP d action completion date

Prevention Detection

1. Sensor Non-Functional 3 1

2. Supporting H/W Non-Functional 3 1

3. Battery / Power Failure 2 1

4. Network / Connect with Trans-Receiver 2 1


Failure

Cloud Connect / Internet Failure 2 1

1. Sensor Failure 3 2

1. Calibration Failure 3 1

2. Installation Failure 3 1

1
1. Calibration Failure 3 3

2. Sensor Failure 3 3

1. Sensor Failure 3 2

2. Caibration Failure 2 2

1. Network Failure 4 1

2. Internet Failure 3 1

3. Power Failure 3 1

1. Design Failure 4 1

2. Communication Failure 4 1

3. Network Failure 4 1

1
1

1. Internet Failure 3 1

2. Network Failure 2 1

1. Sensor Failure 3 2

2. Network Failure 3 2

3. Internet Failure 3 2

1. Sensor Failure 3 1

2. Software Failure 3 1

3. Calibration Failure 2 1

1. Software Failure 2 1

1
1

1. Sensor Failure 3 3

2. Calibration Failure 4 3

3. Design Failure (Cable Side) 4 3

1. Network Failure 3 3

2. Internet Failure 3 3

1. Design Failure 3 3

2. Sensor Failure 3 3

3. Calibration Failure 2 3

1. Calibration Failure 3 3

2. Software Failure 3 3
3

1. Sensor Failure 3 2

2. Calibration Failure 2 2

1. Battery Failure 3 1

2. Wire / Design Failure 4 1

1. Battery Failure 3 1

2. BMS Failure 3 1

1. Battery Failure 3 1
2. Design Failure (Battery Damage) 3 1

1. BMS Failure 3 1

1. Battery Failure 2 1

1. Ingress Protection Design Failure 3 2

1. Design Failure 4 1
2. Human Interference 4 1

1. Design Failure 3 1

2. Human Interference 3 1

1. Design Failure 1 1

1
1
1
1

1. Design Failure 1 1

1
1
1
1

1. Design Failure 1 1

1
1
1
1
1. Design Failure 4 3

2. Process Failure 6 3

1. Process Failure 6 2

2. Design Failure 4 2

2
DFMEA Action results

Actions taken SEV OCC DET DFMEA AP


Sub System Item / Function Primary / Priority 1 / 2 Potential Failure Mode
Secondary

LOAD Detection of load at all Primary 1 No detection / reflection


DETECTION the time of the load
SYSTEM

Consistent detection of Primary 1 Showing inconsistant


load at all the time values
Correct detection of Primary 1 Incorrect values /
load at all the time malfunctioning over the
period

Reflected Values Priamary 1 Measured values are


should be within the beyond the tolerance
tolerence limits limits

Should not create false Primary 2 Triggering Alerts without


positive alerts event or reflecting
excessive values for
small events

Communication of Primary 1 No communication


values to server at
schedules intervals
Communication of Primary 1 No communication
values to server at
schedules intervals

Continuous data Primary 1 Intermittent


delivery, unaffected communication due to
by climate situations situation like rain and
sunlight,

Data delivery Primary 1 delay in communication


without undue
delay beyond the
scheduled intervals

Stable data delivery Primary 1 Fluctuations in


at all the times communication
Load data for Priamry 1 No change in the load
immediate event is
provided

Data for cumulative Secondary 1 Sometimes values is


load is provided geting updated
sometimes not.

No False Negative Primary 1 getting values lesser


Scenario than actual load

Load Data reflection Secondary 1 there may loss in the


at the UI data packets in between
due to wireless network
at the UI data packets in between
due to wireless network

Alerts to be received Secondary 1 Load Sensor System not


based on severity triggering alerts
levels agreed

If there is an Secondary 2 certain load is detected


anomaly, it must be but no alerts triggered
easy to detect

System should not Secondary 1 sometimes certain load


get hanged or give is detected sometimes
irrational data actual load is detected
Battery backup and Primary 1 No battery power
robustness should received
servive device for
long backup.

Battery Performance Primary 2 Battery powered


should be in sync insufficient current,
with the power causes some function to
profiling work and some not.
requirement

Battery should last Secondary 1 Battery is giving backup


for the stipulated lesser than exptected
period
Sesnor System Secondary 1 Battery is providing
should achieve higher current than
maximum period of expected or battery is
serviceability giving higher backup
than expected.

Sensor Function Primary Battery is not constantly


Shouldn't be providing current, it
afffected by varies continously.

Device should be Secondary 1 Damaged enclouser due


water / humidity to heavy object falls on it
damage proof and / damaaged due to
should be easy to water / humidity entry. It
carry and has not handle to carry
installation..

Device should be Secodary 1 Device Damage or Theft


theft resistant and
should be robust
Device should be Secondary 1 Due to damage, it may
impact resistant and happen some functions
Ingress Protected may work due to cut in
wiring.

Device should pass Secondary 1 No hole for deplyment at


anchor rod all the anchor
way accross through
device hole.

Device Should Secondary 1 hole is present but given


mount accurately on diameter are inaccurate.
the anchor

Device Cables Secondary 1 Device cables not


Should be of correct fabricated for designed
dimensions lengths
Easy for Secondary 2 Very hard to maintaince.
mantainance. Everytime need to take
device down and open
for any mantainance is
time and money
investing.

Long Term Secondary 2 Previously maintainance


maintenance should was easy but now due to
be easy some reason it is difficult
to make the
maintanance.
Potential Effects of Failure SEV C Potential Causes/ Mechanisms OCC
L of failure
A
S
S
I
F
NHA - No signal at hardware assembly stage/ Loss 8 I 1. Sensor Non-Functional 3
of priamary function C
A
T
I
O
N

Customer - No Effect as of now but need to be 1 (8) 2. Supporting H/W Non- 3


captured (it is loss of primary function if it gets
captured) Functional

End user - Warning detection function fails, loss of 8 3. Battery / Power Failure 3
primary function.

Safety and Regulatory - 10 4. Network / Connect with 4


loss of lives & loss of property without warning,
Trans-Receiver Failure

Legal : 10 5. Wrong Sensor selection 2


Legal Action: loss of revenue & reputation.

NHA - Fluctuation of value at hardware assemly 8 1. Sensor Failure 3


stage/ Loss of priamary function

Customer –will get alert over email or SMS about 8


system as well as pysically on site there will be
indication.

End user - Warning detection function partially 10


fails, loss of primary function.

Safety and Regulatory - 10


loss of lives & loss of property without warning,

Legal : 10
Legal Action: loss of revenue & reputation.
NHA - incorrect value at hardware assemly stage/ 10 1. Calibration Failure 3
Loss of priamary function

Customer -No Effect as of now but need to be 10 2. Installation Failure 3


captured

End user - may get incorrect values and false 10


trigger of the system.Or event may not captured,
loss of primary function.

Safety and Regulatory - 10


loss of lives & loss of property without warning,

Legal : 10
Legal Action: loss of revenue & reputation.

NHA – inaccurate trigger of event at hardware 8 1. Calibration Failure 3


assemly stage/ Loss of primary function

Customer - No Effect as of now but need to be 8 2. Sensor Failure 3


captured

End user - may get incorrect trigger of an event to 8


the system.Or event may not captured , loss of
primary function.

Safety and Regulatory - 10


loss of lives & loss of property without warning,

Legal : 10
Legal Action: loss of revenue & reputation.

NHA – No trigger of event at hardware assemly 10 1. Sensor Failure 3


stage/ Loss of primary function

Customer - No Effect as of now but need to be 10 2. Caibration Failure 2


captured

End user – may not get trigger of an event to the 10


system.Or event may not captured, loss of primary
function.

Safety and Regulatory - 10


loss of lives & loss of property without warning,

Legal : 10
Legal Action: loss of revenue & reputation.

NHA – Delayed communication at hardware 10 1. Network Failure 4


assemly stage/ Loss of primary function
Customer –will get alert over email or SMS about 9 2. Internet Failure 3
system as well as pysically on site there will be
indication.

End user – Warning detection function fails, loss of 10 3. Power Failure 3


primary function.

Safety and Regulatory - 10


loss of lives & loss of property without warning,

Legal : 10
Legal Action: loss of revenue & reputation.

NHA – Interrupted communication at hardware 10 1. Design Failure 4


assemly stage/ Loss of primary function

Customer – will get alert over email or SMS about 8 2. Communication Failure 4
system as well as pysically on site there will be
indication.

End user – Warning detection function fails, loss of 10 3. Network Failure 4


primary function.

Safety and Regulatory - 10


loss of lives & loss of property without warning,

Legal : 10
Legal Action: loss of revenue & reputation.

NHA –No communication at the right time or no 7 1. Internet Failure 3


realtime event captured at hardware assemly
stage/ Loss of primary function

Customer – will get alert over email or SMS about 10 2. Network Failure 2
system as well as pysically on site there will be
indication.

End user – Warning detection function fails, loss of 10


primary function.

Safety and Regulatory - 10


loss of lives & loss of property without warning,

Legal : 10
Legal Action: loss of revenue & reputation.

NHA –No communication at the right time or no 10 1. Sensor Failure 3


realtime event captured at hardware assemly
stage/ Loss of primary function

Customer – will get alert over email or SMS about 10 2. Network Failure 3
system as well as pysically on site there will be
indication.

End user – Warning detection function fails, loss of 10 3. Internet Failure 3


primary function.

Safety and Regulatory - 10


loss of lives & loss of property without warning,
Legal : 10
Legal Action: loss of revenue & reputation.

NHA –No event will be generated if there is any at 8 1. Sensor Failure 3


hardware assemly stage/ Loss of primary function

Customer – No Effect as of now but need to be 8 2. Software Failure 3


captured (it is loss of primary function if it gets
captured)

End user – Warning detection function fails, loss of 8 3. Calibration Failure 2


primary function.

Safety and Regulatory - 10


loss of lives & loss of property without warning,

Legal : 10
Legal Action: loss of revenue & reputation.

NHA –No right event will be generated if there is 8 1. Software Failure 2


any at hardware assemly stage/ Loss of primary
function.

Customer – will get alert over email or SMS about 8


system as well as pysically on site there will be
indication.

End user – Warning detection function fails, loss of 10


primary function.
Safety and Regulatory - 10
loss of lives & loss of property without warning,

Legal : 10
Legal Action: loss of revenue & reputation.

NHA –No event or event savirity will not be 8 1. Sensor Failure 3


generated at hardware assemly stage/ Loss of
primary function.

Customer - No Effect as of now but need to be 10 2. Calibration Failure 4


captured (it is loss of primary function if it gets
captured)

End user – Warning detection function fails, loss of 10 3. Design Failure (Cable Side) 4
primary function.

Safety and Regulatory - 10


loss of lives & loss of property without warning,

Legal : 10
Legal Action: loss of revenue & reputation.

NHA - No signal at hardware assemly stage/ Loss of 10 1. Network Failure 3


priamary function

Customer – will get alert over email or SMS about 10 2. Internet Failure 3
system as well as pysically on site there will be
indication.
End user – Warning detection function fails, loss of 10
primary function.
Safety and Regulatory - 10
loss of lives & loss of property without warning,

Legal : 10
Legal Action: loss of revenue & reputation.

NHA – Lack of trigger of an event at hardware 10 1. Design Failure 3


assemly stage/ Loss of priamary function

Customer – will get alert over email or SMS about 10 2. Sensor Failure 3
system as well as pysically on site there will be
indication.

End user – Warning detection function fails, loss of 10 3. Calibration Failure 2


primary function.

Safety and Regulatory - 10


loss of lives & loss of property without warning,

Legal : 10
Legal Action: loss of revenue & reputation.

NHA – Lack of trigger of an event at hardware 10 1. Calibration Failure 3


assemly stage/ Loss of priamary function

Customer – No Effect as of now but need to be 10 2. Software Failure 3


captured (it is loss of primary function if it gets
captured)

End user – Warning detection function fails, loss of 10


primary function.

Safety and Regulatory - 10


loss of lives & loss of property without warning,

Legal : 10
Legal Action: loss of revenue & reputation.

NHA – Inconsistant reporting of an event at 10 1. Sensor Failure 3


hardware assemly stage/ Loss of priamary function

Customer – will get alert over email or SMS about 8 2. Calibration Failure 2
system as well as pysically on site there will be
indication.

End user – Warning detection function fails, loss of 10


primary function.
Safety and Regulatory - 10
loss of lives & loss of property without warning,

Legal : 10
Legal Action: loss of revenue & reputation.

NHA – No power to the device at hardware 10 1. Battery Failure 3


assemly stage/ Loss of priamary function

Customer – will get alert over email or SMS about 10 2. Wire / Design Failure 4
system as well as pysically on site there will be
indication.

End user – Warning detection function fails, loss of 10


primary function.

Safety and Regulatory - 10


loss of lives & loss of property without warning,

Legal : 10
Legal Action: loss of revenue & reputation.

NHA – Signal will not be received or incomplete 10 1. Battery Failure 3


information at hardware assemly stage/ Loss of
priamary function

Customer – will get alert over email or SMS about 10 2. BMS Failure 3
system as well as pysically on site there will be
indication.

End user – Warning detection function fails, loss of 10


primary function.
Safety and Regulatory - 10
loss of lives & loss of property without warning,

Legal : 10
Legal Action: loss of revenue & reputation.

NHA – Insufficient Power to the hardware assemly 8 1. Battery Failure 3


stage/ Loss of priamary function

Customer : will get alert over email or SMS about 8 2. Design Failure (Battery Da 3
system as well as pysically on site there will be
indication.

End user – Warning detection function fails, loss of 8 3. Incorrect Power Profiling 2
primary function.

Safety and Regulatory - 10


loss of lives & loss of property without warning,

Legal : 10
Legal Action: loss of revenue & reputation.
NHA – Higher current spur at hardware assembly 2 1. BMS Failure 3
stage / No loss of primary function.

Customer: 2

End user – No effect on live detection function, No 2


loss of primary function.

Safety and Regulatory - 2

Legal : 2
Legal Action:

NHA – Signal will not be received or incomplete 10 1. Battery Failure 2


information at hardware assemly stage/ Loss of
priamary function

Customer – will get alert over email or SMS about 10


system as well as pysically on site there will be
indication.

End user – Warning detection function fails, loss of 10


primary function.
Safety and Regulatory - loss of lives & loss of 10
property without warning
Legal : Legal Action: loss of revenue & reputation. 10

NHA – Ingress Damage at hardware assemly stage/ 10 1. Ingress Protection Design F 3


Loss of priamary function

Customer: will get alert over email or SMS about 10


system as well as pysically on site there will be
indication.

End user – Warning detection function fails, loss of 10


primary function.

Safety and Regulatory - loss of lives & loss of 10


property without warning
Legal : Legal Action: loss of revenue & reputation. 10

NHA – Signal will not be received or incomplete 10 1. Design Failure 4


information at hardware assemly stage/ Loss of
priamary function

Customer: will get alert over email or SMS about 10 2. Human Interference 4
system as well as pysically on site there will be
indication.
End user – Warning detection function fails, loss of 10
primary function.

Safety and Regulatory - loss of lives & loss of 10


property without warning

Legal : Legal Action: loss of revenue & reputation. 10

NHA – Signal will not be received or incomplete 10 1. Design Failure 3


information at hardware assemly stage/ Loss of
priamary function

Customer: will get alert over email or SMS about 10 2. Human Interference 3
system as well as pysically on site there will be
indication.

End user – Warning detection function fails, loss of 10


primary function.
Safety and Regulatory - loss of lives & loss of 10
property without warning
Legal : Legal Action: loss of revenue & reputation. 10

NHA – Cannot fit / install to system, No signal / 10 1. Design Failure 1


function at hardware assemly stage/ Loss of
priamary function

Customer: It is captured. 10
End user – 10
Safety and Regulatory - 10
Legal : Legal Action: 10

NHA – Cannot fit / install properly to system, No 8 1. Design Failure 1


signal / function at hardware assemly stage/ Loss
of priamary function

Customer: It is captured. 8
End user – 8
Safety and Regulatory - 8
Legal : Legal Action: 8

NHA – Cannot fit / install properly to system, No 8 1. Design Failure 1


signal / function at hardware assemly stage/ Loss
of priamary function

Customer: It is captured. 8
End user – 8
Safety and Regulatory - 8
Legal : Legal Action: 8
NHA – Difficult Maintenance process. 8 1. Design Failure 4

Customer: will get alert over email or SMS about 8 2. Process Failure 6
maintainance of system as well as pysically on site
there will be indication.

End user – loss of primary function during 8


maintanance.
Safety and Regulatory - loss of lives & loss of 10
property without warning
Legal : Legal Action: loss of revenue & reputation. 10

NHA – Repeated Maintenance Difficult 8 1. Process Failure 6

Customer: will get alert over email or SMS about 8 2. Design Failure 4
maintainance of system as well as pysically on site
there will be indication.

End user – loss of primary function during 8


maintanance.
Safety and Regulatory - loss of lives & loss of 10
property without warning
Legal : Legal Action: loss of revenue & reputation. 10
Current Design controls Current Design controls DET DFMEA Recommended action
AP

Prevention Detection

1. Standard Make & Certified 2. 1. Controller is programmed to detect 6 1. Multi-Sensor Architecture


QC and Lab Check before integration 3. and report Sensor failure to mitigate individual sensor
System testing before and after fabrication loss 2. OTA control to
for performance and data flow. confirm temporary problem or
permenant damage

1. Standard Make & Certified components 1. Controller is programmed to detect 3 1. Eliminate wiring and build
2. Minimal wiring and report circuit failure completely wireless circuit
structure inside 3. QC and Lab
Check before integration
4. System testing before and
after fabrication for performance and data
flow

1. Standard Make & Branded Batteris 2. 1. Fixed Battery enclosure and 1 1. Use of Lithium Ion or
Alkaline and leak proof batteries connectors Sodium Ion Batteries
1. Use of reliable communication protocol 1. External Antenna 1 1. Use of Silicon coated
like a Bluetooth 2. Antenna antenna heads to minimise
and Receiver white listed connect climate related damage

1. Use of Sensor with specific application, 1. BOM selection criterion is well defined 1
specifications and standard make.

1. Standard Make & Certified 2. 1. Controller is programmed to detect 2


QC and Lab Check before integration 3. and report Sensor failure
System testing before and after fabrication
for performance and data flow.

2
1. Evolved and Calibrated Algorithm 1. Peer Testing Procedure 2 1. Coninued testing of
2. Stringent Lab Testing with Third 2. Pre-set calbration Sensors with the help of
Party Labs involved 3. Comaprison with matching registered labs
with alternate platform
1. Specific Angles and Alignment for 1. QC and Lab Testing after 1
Sensors 2. fabrication
Cutomised Box Design
1

1. Evolved and Calibrated Algorithm 1. Peer Testing Procedure 3


2. Stringent Lab Testing with Third 2. Pre-set calbration
Party Labs involved 3. Comaprison with matching
with alternate platform

1. Standard Make & Certified 2. 1. Controller is programmed to detect 3


QC and Lab Check before integration 3. and report Sensor failure
System testing before and after fabrication
for performance and data flow. 3

1. Standard Make & Certified 2. 1. Controller is programmed to detect 2


QC and Lab Check before integration 3. and report Sensor failure
System testing before and after fabrication
for performance
1. Evolved andandCalibrated
data flow. Algorithm 1. Peer Testing Procedure 2
2. Stringent Lab Testing with Third 2. Pre-set calbration
Party Labs involved 3. Comaprison with matching
with alternate platform
2

1. Use of established plaforms like BLE, 1. Handshake coding ensures 1


Lo-Ra, Wi-Fi etc. 2. immediate detetction of network or
Secured Connection data loss
1. Use of established GPRS service 1. Handshake coding ensures 1
providers like Airtel, Jio etc. immediate detetction of network or
2. Secured Connection data loss
1. The system is supported by dual 1. Realtime Power status is 1
power source of Solar and monitored and reflected on the UI
Rechargeable Batteries
1

1. Ingress Protection standard of IP 65 is 1. Climate data is used to relate 1


achieved system failure

1. Use of established GPRS service 1. Handshake coding ensures 1


providers like Airtel, Jio etc. immediate detetction of network or
2. Secured Connection data loss

1. Use of established plaforms like BLE, 1. Handshake coding ensures 1


Lo-Ra, Wi-Fi etc. 2. immediate detetction of network or
Secured Connection data loss
1

1. Use of established GPRS service 1. Handshake coding ensures 1


providers like Airtel, Jio etc. immediate detetction of network or
2. Secured Connection data loss

1. Use of established plaforms like BLE, 1. Handshake coding ensures 1


Lo-Ra, Wi-Fi etc. 2. immediate detetction of network or
Secured Connection data loss
1

1. Standard Make & Certified 2. 1. Controller is programmed to detect 2


QC and Lab Check before integration 3. and report Sensor failure
System testing before and after fabrication
for performance
1. Use and data
of established flow. like BLE,
plaforms 1. Handshake coding ensures 2
Lo-Ra, Wi-Fi etc. 2. immediate detetction of network or
Secured Connection data loss

1. Use of established GPRS service 1. Handshake coding ensures 2


providers like Airtel, Jio etc. immediate detetction of network or
2. Secured Connection data loss
2
2

1. Standard Make & Certified 2. 1. Controller is programmed to detect 1


QC and Lab Check before integration 3. and report Sensor failure
System testing before and after fabrication
for performance codes
1. Established and data
andflow.
algorithms are 1. Multi-Sensor raw machine data 1
well tested for failures can immediately detect the
software failure

1. Evolved and Calibrated Algorithm 1. Peer Testing Procedure 1


2. Stringent Lab Testing with Third 2. Pre-set calbration
Party Labs involved 3. Comaprison with matching
with alternate platform
1

1. Established codes and algorithms are 1. Multi-Sensor raw machine data 1


well tested for failures can immediately detect the
software failure
1

1. Standard Make & Certified 2. 1. Controller is programmed to detect 3


QC and Lab Check before integration 3. and report Sensor failure
System testing before and after fabrication
for performance
1. Evolved andandCalibrated
data flow. Algorithm 1. Peer Testing Procedure 3
2. Stringent Lab Testing with Third 2. Pre-set calbration
Party Labs involved 3. Comaprison with matching
with alternate platform
1. Cables are pre-designed and verified 1. Can be immdiately detected 3 1. Try to design cables,
before installation during manual installation process whose lenghth can be
adjusted at site
3

1. Use of established plaforms like BLE, 1. Handshake coding ensures 3


Lo-Ra, Wi-Fi etc. 2. immediate detetction of network or
Secured Connection data loss
1. Use of established GPRS service 1. Handshake coding ensures 3
providers like Airtel, Jio etc. immediate detetction of network or
2. Secured Connection data loss
3

1. Load Cables and Couplings are pre- 1. Can be immdiately detected 3


designed and verified before during manual installation process
installation

1. Standard Make & Certified 2. 1. Controller is programmed to detect 3


QC and Lab Check before integration 3. and report Sensor failure
System testing before and after fabrication
for performance and data flow.

1. Evolved and Calibrated Algorithm 1. Peer Testing Procedure 3


2. Stringent Lab Testing with Third 2. Pre-set calbration
Party Labs involved 3. Comaprison with matching
with alternate platform

1. Evolved and Calibrated Algorithm 1. Peer Testing Procedure 3


2. Stringent Lab Testing with Third 2. Pre-set calbration
Party Labs involved 3. Comaprison with matching
with alternate platform
1. Established codes and algorithms are 1. Multi-Sensor raw machine data 3
well tested for failures can immediately detect the
software failure
3

1. Standard Make & Certified 2. 1. Controller is programmed to detect 2


QC and Lab Check before integration 3. and report Sensor failure
System testing before and after fabrication
for performance and data flow.

1. Evolved and Calibrated Algorithm 1. Peer Testing Procedure 2


2. Stringent Lab Testing with Third 2. Pre-set calbration
Party Labs involved 3. Comaprison with matching
with alternate platform
2
2

1. Standard Make & Branded Batteris 2. 1. Fixed Battery enclosure and 1


Alkaline and leak proof batteries connectors

1. System boards have been designed 1. Controllers are programmed to 1


to be integrated and embedded detect and report any disconnect
2. Interface connectors are are of due to power failure
standard make and fit 2. Battery status is monitored on a
realtime basis

1. Standard Make & Branded Batteris 2. 1. Fixed Battery enclosure and 1


Alkaline and leak proof batteries connectors

1. Battery and system performance is 1. Raw Machine data delivers the 1


tested after the power profiling power supply status on a realtime
procedure and reports are documneted basis.

1. Standard Make & Branded Batteris 2. 1. Fixed Battery enclosure and 1


Alkaline and leak proof batteries connectors
1. Ingress Protection standard of IP 65 is 1. Battery Status is reported on a 1
achieved realtime basis

1Power suppy to each component and 1. Raw Machine data delivers the 1
system performance is tested and power supply status on a realtime
verified after the power profiling basis.
procedure and reports are documneted

1
1. Power supply to each component 1. Raw Machine data delivers the 1
and system performance is tested after power supply status on a realtime
the power profiling procedure and basis.
reports are documneted

1. Standard Make & Branded Batteris 2. 1. Fixed Battery enclosure and 1


Alkaline and leak proof batteries connectors

1. Ingress Protection standard of IP 65 is 1. Climate data is used to relate 2 Increase IP Rating to 67


achieved system failure

1. Device has been made rugged and 1. Controller detects impact and loss 1
tamper resistant of signal going out of range

1. Ergonomically and materially made 1 1. To include Hall Effect


non-attractive sensors for theft detection
2. Bolts and fasteners are of 2.
uncoventional designs Vibration analysis to
detect human interference
leading to damage or
theft.
1

1. Device has been made rugged and 1. Controller detects loss of signal 1
tamper resistant

1. Wire cables are of standard make 1


with requsite tamper proof ratings.

1. Design and Fabrication are adhering 1. Detectable due to manual 1


to specifications and site requirements presence during the installation

1
1
1
1

1. Design and Fabrication are adhering 1. Detectable due to manual 1


to specifications and site requirements presence during the installation

1
1
1
1

1. Design and Fabrication are adhering 1. Detectable due to manual 1


to specifications and site requirements presence during the installation

1
1
1
1
1. Design and Fabrication are adhering 1. Detectable due to manual 3
to specifications and project presence during the installation
requirements e.g. 'handle' at the top 2.
Specific tools for the project during
installation and maintenance.

3 Detailed SoP document


and manuals to be
prepared for installation
and maintenance

2
Responsibility & target DFMEA Action results
completion date

Actions taken SEV OCC DET DFMEA AP

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