1.FS1 - RETRACTOR - FMEA - REV001 - 20220927 - Spool - Base 2

SYSTEM NAME: FS1 RETRACTOR ASSEMBLY
Which is the weakest component in the

COMPONENT : SPOOL strength of the retractor?
Manufacturing Lot information: 1 Lot = 150000, Cavities = 4

POTENTIAL CAUSE/MECHANISM OF FAILURE Impact of failure
Countermeasure
Sl No Component Function Mode of Failure Severity Occurrence Countermeasures CPK
rank
Primary Cause Secondary cause System Level Vehicle Level
A:2.8mm
[Specification] A: Shaft diameter 2.8±0.05mm,
B: Shaft diameter 2.8±0.05mm,
B:2.8mm
[Manufacturing control]: 3 pieces per lot Strength study
Inspection method: VMM A - 1.807
Rotate during webbing extraction and Occupant cannot be
1 Cannot rotate Spool Deformation Insufficient Strength Belt cannot be fastened 4 2 B
retraction restrained [SPEC] IS15140 / ECE R16 B - 1.812
Locking performance check,
[SPEC] As per Suzuki requirement
Durability test 75000 cycles
vibration High/Low load

[SPEC] IS15140/ECE R16 durabiliy
2 ↑ ↑ ↑ Repetition load ↑ ↑ 4 2 B
[SPEC] Suzuki requirement
Durability test - 75000 cycles
C: 19.55mm D: 17.55mm
B: 48.5mm
[Specification]: A: 88.6±0.2mm ,B: 48.5±0.1mm,C: 19.55mm,D: 17.55mm clearance study

[Manufacturing control]: 3 piece per lot
Inspection method: VMM A - 3.4
3 ↑ ↑ Shaft's thrust interference Thrust direction out of dimension ↑ ↑ 4 2 B B - 2.760

[SPEC] IS15140/ECE R16
Locking performance check, Extraction/retraction force measurement C - 2.126
Durability test - 75000 cycles D - 1.651
A: 88.6mm
[Specification]: Spool (reel) Diameter average (φ32.85)

[Manufacturing Control]: Parameters check as per control plan for every lot production (Component supplier)
[SPEC] IS15140/ECE R16 static strength Strength study

Test part: Retractor
Condition: 450mm WoS, 100mm/min speed of load application
Retractor assembly not Requirement: 9.8kN
Withstand load by the webbing in locking Can't withstand webbing
4
condition pulling load
Deformation Insufficient Strength meeting strength ↑ 4 2 B
requirement φ32.85
mm
[Manufacturing control]: Parameters check as per control plan for every lot production Control parameters
[SPEC] IS15140 / ECE R16 static strength
5 ↑ ↑ ↑ Spool Manufacturing Defects ↑ ↑ 4 2 B
Condition: 450mm WoS, 100mm/min speed of load application blowhole, Burr
Requirement: 9.8kN
Material : ADC 12,

[Manufacturing Control]: Inpection of Material upon receiving of raw material 1/batch & Mill sheet verification. Content of recycled
materials
6 ↑ ↑ ↑ Wrong Spool Material ↑ ↑ 4 2 B [SPEC] IS15140 / ECE R16 static strength
Requirement: 9.8kN
[SPEC] IS15140/ECE R16 Corrosion resistance

7 ↑ ↑ ↑ Corrosion ↑ ↑ 4 2 B
Condition: 50 hrs in Salt spray chamber and 24 hrs drying in room temperature
Requirement: No Rust
thermal shock
[SPEC] As per IS 15140 / ECE R16, Dynamic sled test post durability cycles
8 ↑ ↑ ↑ Environmental deterioration ↑ ↑ 4 2 B
8.8
mm
[Specification]: A: 8.8±0.15mm B: Profile 0.15

Inspection method: CMM
A: 2.094
Mesh with the Base
9
Gear when holding strength
Does not mesh with Base Gear out of phase Poor shape ↑ ↑ 4 2 B
B: 1.574
Locking performance check, Extraction/retraction force measurement
Durability test - 75000 cycles Strength study
drop test High/Low load

[SPEC] As per IS15140 / ECE R16, Dynamic sled test post durability cycles durabiliy
10 ↑ Cannot Retain meshing Gear deformation Damage due to impact load ↑ ↑ 4 2 B
Roughness
[Specification]: As per Suzuki requirement
11 ↑ ↑ ↑ Gear wears out due to repetitive load ↑ ↑ 4 2 B
Durability test - 75000 cycles
[Manufacturing control]: Parameters check as per control plan for every lot production (Component supplier) blowhole, Burr
12 ↑ ↑ ↑ Casting short shot ↑ ↑ 4 2 B
Requirement: 9.8kN
[Manufacturing control]: Parameters check as per control plan for every lot production
Control parameters
Requirement: 9.8kN

14 ↑ ↑ ↑ Corrosion ↑ ↑ 4 2 B
thermal shock
[SPEC] As per IS15140 / ECE R16, Dynamic sled test post durability cycles
6.6mm
[Specification]: Gear thickness A: 6.6±0.15mm & B: Gear phase 0.15

A: 2.228
Keep the meshing Does not mesh with the
16
with the Base Gear Base Gear
Gear is out of phase
Poor shape ↑ ↑ 4 2 B
[SPEC] IS15140/ECE R16 static strength
B: 1.85
Requirement: 9.8kN Strength study
High/Low load
durabiliy
17 ↑ Cannot keep the meshing Gear deformation damage Damage due to impact load ↑ ↑ 4 2 B [SPEC] As per IS15140 / ECE R16, Dynamic sled test post durability cycles
Roughness
[Specification]: Suzuki requirement
18 ↑ ↑ ↑ Gear wears out due to repetitive load ↑ ↑ 4 2 B
Durability test - 75000 cycles & Dynamic load test
[Manufacturing control]: Parameters check as per control plan for every lot production (Component supplier)

blowhole, Burr
Requirement: 9.8kN
[Manufacturing control]: Parameters check as per control plan for every lot production
Control parameters
Requirement: 9.8kN

21 ↑ ↑ ↑ Corrosion ↑ ↑ 4 2 B
thermal shock
22 ↑ ↑ ↑ Environmental deterioration ↑ ↑ 4 2 B [SPEC] As per IS15140 / ECE R16, Dynamic sled test post durability cycles
Strength study
[Specification]: Spool Flange Diameter A: Ø46 & B: Ø46 & C: Profile tolerance 0.2mm
[Manufacturing control]: Dimension inspection - 3 per lot
A: 1.99
Inspection method: VMM
φ46mm
φ46mm
Shaft dropping out from the

23 Prevent Spool from dropping out of the base
base
Flange deformation Damage Insufficient strength ↑ ↑ 4 2 B
B: 1.87
C: 1.84
Requirement: 9.8kN
blowhole, Burr

Requirement: 9.8kN
Which
is the
[Manufacturing
weakes control]: Parameters check as per control plan for every lot production (Component supplier)
t Control parameters
compo IS15140 / ECE R16 static strength
[SPEC]
25 ↑ ↑ ↑ Spool Manufacturing Defects ↑ ↑ 4 2 B nent in
Test
the part: Retractor
Condition:
strengt 450mm WoS, 100mm/min speed of load application
Requirement:
h of 9.8kN
the
retract
or?
[Specification] A: Spool tip Radius 1.45mm±0.05mm & B - Spool tip Radius 1.45mm±0.05mm

Locking performance check, Extraction/retraction force measurement
A: 1.801
Spool bearing radius is not as per requirement Durability test - 75000 cycles
26 ↑ ↑ (Sensor and spring side)
Spool stuck & not rotating ↑ ↑ 4 2 B
B: 1.62
[Specification]: 0.2mm
Parting Line(PL) Burr deburring process/surface finishing
Inspection method: Visual inspection & Aesthetic check for burrs.
27 No Web cut during loading Web cut during loading Shape defect Parting line Burrs ↑ ↑ 4 2 B [SPEC] IS15140 / ECE R16 static strength
Requirement: 9.8kN
Control parameters
Requirement: 9.8kN
Severity Rank Definition Frequency of Occurrence Definition
Serious breakdown that affects human life 4 Often occurs Carryover design which as caused failure
Serious breakdown to the vehicle Similar design which as caused failure
4 3 Can occur
It doesn't work Failure occurred during development
Non-compliance with regulations 2 Less occurs Similar design which is in mass production
Significant loss of function 1 Rarely occurs Failure will not occur
3
Doesn't work and is unpleasant
2 Partial loss of functionality Countermeasure Rank
1 Little impact A Change the design
Test result or
B
Post process Inspection
C Without measures
COMPONENT : RETRACTOR BASE

Manufacturing Lot information: 1 Lot = 20000
Countermeasure
rank
[Specification]: A: Hole Diameter11.3mm+0.2mm, B: Wall thickness 19mm
[Manufacturing control]: Dimension inspection - 3 per lot
Inspection method: VMM / Vernier

Requirement: 9.8kN A: 1.47
Cannot withstand Occupant cannot be
1 Absorbs anchorage load
Anchorage load
Secondary cause Insufficient strength Cannot hold strength
restrained
4 2 B Strength study B: 1.60
11.3 +0.2
Strength study
R19
[Specification]: A: Thickness control: 1.5 ±0.06,

[Manufacturing control]: 3 per batch of roll
Inspection method: Vernier / Micometer
[Specification]: S550 MC, Inpection of Material upon receiving of parts(1/batch) & Mill sheet checking.
Strength study
2 ↑ ↑ ↑ Different material ↑ ↑ 4 2 B A: 1.84
Requirement: 9.8kN
Surface treatment: Pre coated steel usage to avoid corrosion

surface treatment
type and thickness
3 ↑ ↑ ↑ Corrosion ↑ ↑ 4 2 B
vibration
[SPEC] As per IS 15140 / ECE R16, Dynamic sled test post durability cycles
[Specification]: A: Base width: 56.5±0.25mm & B: Angle 90±0.36

[Manufacturing control]: In house base bending process, LVDT checking - 100% check in production line

5 Hold the spool in its position Spool coming out of base Deformation/breakage of width across flats Poor shape ↑ ↑ 4 2 B Requirement: 9.8kN
Lap and clearance

study
A: 1.89
B: 1.489
6 ↑ ↑ ↑ Insufficient strength ↑ ↑ 4 2 B
High/Low load vibration

durabiliy
7 ↑ ↑ ↑ Repetitive Load ↑ ↑ 4 2 B
High speed tensile Drop test

8 ↑ ↑ ↑ Impact Load ↑ ↑ 4 2 B [SPEC] As per IS15140 / ECE R16, Dynamic sled test post durability cycles strength
Surface treatment: Pre coated steel usage to avoid corrosion

9 ↑ ↑ ↑ Corrosion ↑ ↑ 4 2 B
thermal shock
10 ↑ ↑ ↑ Environmental deterioration ↑ ↑ 4 2 B [SPEC] As per IS15140 / ECE R16, Dynamic sled test post durability cycles
[Specification]: A: Profile 0.3 In house crimping operation crimping

[Manufacturing Control]: Dimension inspection - 3 per lot 0.3?
[Inspection] B: Crimped Width : 9.15±0.25mm After crimping in assy line 2nos
Tie bar falling off from
checking per model. Tie bar A: 1.908
11 ↑ Retractor Base
Tie Bar falling off Defective crimping ↑ ↑ 4 2 B strength
B: 1.42
Requirement: 9.8kN
[Specification]: A: Profile tolerance on inner & B: outer contour of the gear
Gear part: 0.2
Circular part: 0.1
Manufacturing control: Dimension inspection 1pc/lot

Test part: Retractor clearance study
Gear area dimension insufficiency - Deformation Requirement: 9.8kN A: 2.710
Interference with Spool Occupant cannot be
12 Rotation of shaft - Allow the shaft to rotate of Gear diameter to be small Belt cannot be unfastened 4 2 B
cannot rotate restrained
Gear part B: 2.235
High/Low load vibration

[Specification]: Suzuki requirement durabiliy
High speed tensile Drop test

14 ↑ ↑ ↑ Impact load ↑ ↑ 4 2 B
[SPEC] As per IS15140 / ECE R16, Dynamic sled test post durability cycles strength
[Specification]: A: Profile 0.1 & B: Profile 0.2

Manufacturing control: Dimension inspection - 1pc/lot

Requirement: 9.8kN
At lock load input

Shaft gear and A: 1.415
shaft gear outer surface
15
and base gear
base gear Insufficient deformation of Base Base shape Defects ↑ ↑ 4 2 B
do not mesh B: 1.575
contact
A
Detail A
[Specification]: A: Locking side hole diameter: 5.0+0.05/-0 (4 locations)

B: Position: φ0.15 (4 locations)
C: Spring side hole diameter: 5.0+0.05/-0 (3 places) clearance study
D: Position: φ0.15 (3 locations)
In-house process control
Manufacturing control: Dimension inspection - Gauge control, 1pc/lot

Requirement: 9.8kN
16 Sensor cover hold with frame Can't hold Drop off due to load Insufficient strength ↑ ↑ 4 2 B
17 ↑ ↑ ↑ Impact Load ↑ ↑ 4 2 B [SPEC] As per IS15140 / ECE R16, Dynamic sled test post durability cycles

4 3 Can occur
3
Test result or
B
C Without measures
COMPONENT : CONTROL LEVER

Component Countermeasure
Sl No Mode of Failure Severity Occurrence Countermeasures CPK
Function rank
[Specification]: A: 9.55±0.1mm B: 12.85±0.1mm

[Manufacturing control]: Dimension inspection - 3pc/lot
Allow shaft to move and A: 9.55mm
Inspection method: Height Gauge B: 12.85mm A: 1.4899
make the shaft gear and
1 W/S not locking Secondary cause Shape Defects Cannot hold strength Occupant cannot be restrained 4 2 B 100% W/S lock check in house production line
base gear to contact
B: 1.893
during locking
As per IS 15140 & ECE R16 - Locking performance check
As per Suzuki spec, Durability test - 75000 cycles
[Specification]: A: Control lever Profile tolerance 0.2 Profile tolerance 0.2

2 ↑ ↑ ↑ ↑ ↑ ↑ 4 2 B 100% W/S lock check in house production line A: 2.2991

Material control: POM delrin 100, Inpection of Material upon receiving of parts (1/batch)
3 ↑ ↑ ↑ Different material ↑ ↑ 4 2 B
4 ↑ ↑ ↑ Environmental deterioration ↑ ↑ 4 2 B [SPEC] As per IS 15140 / ECE R16, Dynamic sled test post durability cycles
3.6mm
2mm
3mm
[Specification]: A: Profile tolerance 0.2 3X

Allow shaft to move and
make the shaft gear and
5
base gear to contact
V/S not working Deformation or damaged Shape defects Cannot hold strength ↑ 4 2 B 100% V/S lock check in house production line A: 1.87
during locking
As per Suzuki spec, Durability test - 75000 cycles laser welding position
[Specification]: A: Control lever stopper profile tolerance 0.2

6 ↑ ↑ ↑ ↑ ↑ ↑ 4 2 B 100% V/S lock check in house production line A: 1.74

Profile tolerance 0.2
Material control: POM delrin 100, Inpection of Material upon receiving of parts(1/batch)
7 ↑ ↑ ↑ Different material ↑ ↑ 4 2 B
8 ↑ ↑ ↑ Environmental deterioration ↑ ↑ 4 2 B [SPEC] As per IS 15140 / ECE R16, Dynamic sled test post durability cycles
[Specification]: Laser welding position: Refer to left figure

Temperature: 270±10°
Spec: V/S assembly peel strength test
A: Strong judgment criteria: 5 Nm or more - 2pcs/angle change
Result: Strength of 6.1Nm for sample after high-speed lock endurance
[Specification]: Sensor assy Angle check : Refer to Right figure

Manufacturing control: Display check - 2pcs/angle change

9 ↑ ↑ V/S not assembled properly Defective laser welding ↑ ↑ 4 2 B A: 1.57
[Specification]: A: Profile tolerance on inner diameter 0.1

100% V/S lock check in house production line

Improper spool
10 ↑ synchronisation with Improper Control lever bearing area Poor Shape ↑ ↑ 4 2 B A: 1.79912
Retractor Base
[Specification]: A: Pin top: Ø2.8±0.03, B: Pin Bottom: Ø3.4±0.03mm, C: Pin Height top 3.13±0.1mm, D: Pin Height bottom 2±0.1mm

A: 1.45
B: 1.64
11 Proper VS locking Improper VS locking Improper Bearing Pin Shape Defects ↑ ↑ 4 2 B
C: 2.421
D: 1.36
[Manufacturing Molding condition management (component supplier)

As per component supplier control plan
12 ↑ ↑ ↑ Molding defects ↑ ↑ 4 4 4
4 3 Can occur
3
Test result or
B
C Without measures
COMPONENT : SENSOR HOUSING

Function System Vehicle rank
Primary Cause Secondary cause
Level Level
[Specification]: A: Profile tolerance 0.2 & B: 0.1

V/S activates when tilt or Cannot hold Occupant cannot

1 V/S not working at set angle Secondary cause Poor shape of housing 4 2 B
occupant detects motion Strength be restrained
A: 1.541
B: 1.799
[Specification]: Profile tolerance 0.1

2 ↑ ↑ Control lever not assembled properly Poor shape ↑ ↑ 4 2 B 100% V/S lock check in house production line

Material control: POM Ultraform N2550 26, Inpection of Material upon receiving of parts(1/batch)

3 ↑ ↑ ↑ Wrong material ↑ ↑ 4 2 B Condition: 450mm WoS, 100mm/min speed of load application
Requirement: 9.8kN

[Specifications] Laser welding position

Temperature: 270±10°
[SPEC] V/S assembly peel strength test - 2pcs/Shift

4 ↑ ↑ ↑ Defective Laser welding ↑ ↑ 4 2 B A: Strong judgment criteria: 5 Nm or more A: 1.57
Result: Strength of 6.1Nm for sample after high-speed lock endurance


4 3 Can occur
3
Test result or
B
C Without measures
COMPONENT : INERTIA DISC

Sl No Component Function Mode of Failure Severity Occurrence Countermeasure rank Countermeasures CPK
[Specification]: A: Profile 0.1

Occupant cannot be
1 W/S working properly W/S not working properly Secondary cause Poor Shape Cannot hold Strength 4 2 B 100% W/S lock check in house production line A: 2.022
restrained
Ø3.7m
[Specification]: A: Ø3.7±0.05 mm m
2 ↑ ↑ ↑ Poor Shape ↑ ↑ 4 2 B A: 2.025

3 ↑ ↑ ↑ Molding Defect ↑ ↑ 4 2 B [SPEC] IS15140/ECE R16

Extraction/Retraction Durability test - 75000 cycles
Material : POM Delrin 100 NC010

[Manufacturing Control]: Inpection of Material upon receiving of raw material 1/batch
4 ↑ ↑ ↑ Wrong Material ↑ ↑ 4 2 B
A: Inertia disc mass : 2.5g MIN

[Manufacturing Control]: Inpection of Material upon receiving
100% W/S lock check in house production line
5 ↑ ↑ ↑ Weight ↑ ↑ 4 2 B A: 2.13

4 3 Can occur
3
Test result or
B
C Without measures
COMPONENT : REINFORCEMENT BAR

Countermeasure
rank
[Specification]: A: Length 56.5mm, B: Width 4, C: Thickness 1.2

Requirement: 9.8kN
A: 1.756
B: 1.45
1 To withstand load Cannot withstand load Secondary cause Poor shape Cannot hold strength Occupant cannot be restrained 4 2 B
C: 1.45
[Manufacturing control]: Parameters check as per control plan for every lot production (Component
supplier)
Reinforcement bar
2 ↑ ↑ ↑ manufacturing defects ↑ ↑ 4 2 B [SPEC] IS15140/ECE R16 static strength
Requirement: 9.8kN
Material : A: Bd 1.2 DIN EN 101040

EN 10139 - DC04+C390(1.0338)
A: 1.49
Requirement: 9.8kN

4 ↑ ↑ ↑ Corrosion ↑ ↑ 4 2 B
4 3 Can occur
3
Test result or
B
C Without measures
COMPONENT : CLUTCH DISC

Function Vehicle rank
Primary Cause Secondary cause System Level
Level
[Specification]: A: Ø43±0.1 & B: Position Ø0.05

Occupant cannot A: 1.56

1 V/S locking properly V/S not locking properly Secondary cause Poor Shape Cannot hold Strength 4 2 B B: 1.42
be restrained

2 ↑ ↑ ↑ Molding Defects ↑ ↑ 4 2 B
Material : POM Bluestarcon BS025A

[Specification]: A - Ø2.9mm+0.05
4 Proper riveting with spool Riveting failure Shape Defect Poor Shape ↑ ↑ 4 2 B Ø2..9mm A: 1.527

Material : POM Bluestarcon BS025A

[Specification]: A: Ø3.7±0.05

As per Suzuki spec, Durability test - 75000 cycles Ø3.7mm
7 Proper W/S locking W/s not locking Shape Defect Poor shape ↑ ↑ 4 2 B A: 1.771

4 3 Can occur
3
Test result or
B
C Without measures
COMPONENT : SENSOR COVER


Function rank
[Specification]: A: Ø5.85±0.05mm, B: Ø4.95±0.05mm, C: Ø2.95±0.05mm (4positions)
D: Position 0.05 & E: Position 0.1 & F: Position 0.1

[Inspection]: Pull out force - In-house process control(Weekly once)
[Testing method]: IS15140/ECE R16 static strength

Requirement: 9.8kN
As per IS15140 / ECE R16, Dynamic sled test
Sensor cover fall out from

1 Does not fall from Base Secondary cause Poor Shape Cannot hold Strength Occupant Cannot be Restrained 4 2 B
Retractor Base


2 ↑ ↑ ↑ Molding Defects ↑ ↑ 4 2 B Test part: Retractor
Requirement: 9.8kN
Material : PP GF40 Thermofil APG40S / 5


3 ↑ ↑ ↑ Wrong Material ↑ ↑ 4 2 B Test part: Retractor
Requirement: 9.8kN
[Specification]: A: Ø4±0.05mm & B:Height : 3±0.1mm

m
m
0.1
3±
Proper Synchronisation Improper Synchronisation A: 1.851

Poor Shape
4 of spool with Retractor of spool with Retractor Shape defect
add repetitive load ↑ ↑ 4 2 B B: 1.67
base base

Material : PP GF40 Thermofil APG40S / 5

[Specification]: A: Flatness 0.2

As per IS 15140 & ECE R16 - Dust 5 hrs

Post locking performance check
Flatness 0.2
7 Proper locking Improper locking Shape defect Dust accumulation ↑ ↑ 4 2 B A: 1.45


4 3 Can occur
3
Test result or
B
C Without measures
COMPONENT : SPRING COVER

Countermeasure
rank
[Specification]: A: Ø5.85±0.05mm, B: Ø4.95±0.05mm, C: Ø2.95±0.05mm (3positions), D: Position 0.1,
E: Position 0.2, F: Position 0.1, G: 32±0.05
[Inspection]: Pull out force - In house process control(Weekly once)

Requirement: 9.8kN
Spring cover fall out from

1 Does not fall from Base Secondary cause Poor Shape Cannot hold Strength Occupant Cannot be Restrained 4 2 B
Retractor Base


Requirement: 9.8kN
Material : POM Hostaform S 9364


Requirement: 9.8kN
[Specification]: A: Flatness 0.2

Improper extraction and Inspection method: CMM
7 Proper extraction and retraction
retraction
Shape defect Dust accumulation Cannot latch the seatbelt ↑ 4 2 B Flatness 0.2 A: 1.56
As per IS 15140 & ECE R16 - Dust 5 hrs
Post locking performance check

4 3 Can occur
3
Test result or
B
C Without measures
COMPONENT : SENSOR BALL

Function System rank
Primary Cause Secondary cause Vehicle Level
Level
[Specification]: A: Roughness : Rmax2.5, B: Diameter of ball 12±0.025mm
Inspection method: Vernier
Inspection method: Roughness check in supplier end as per component supplier control plan

Cannot Hold Occupant cannot be Locking performance check, Extraction/retraction force measurement B: 12mm - 1.412
1 V/S locking Improper V/S locking Secondary cause Poor Shape 4 2 B [SPEC] Suzuki requirement
Strength restrained
Extraction/Retraction Durability test - 75000 cycles
Material : X30 Cr 13

4 3 Can occur
3
Test result or
B
C Without measures
COMPONENT : MOTOR SPRING

Function System rank
Primary Cause Secondary cause Vehicle Level
Level
[Specification]: A: Width 8 -0.1, B: Length = X (based on TF required) ,
C: Thicknesss = X (based on TF required)
Manufacturing control: Inspection at supplier end.
Inspection method : Vernier & scale

Extraction and Retraction Force test
A: 2.280
Proper Extraction and Improper Extraction and Cannot wear Occupant cannot be B: 2.076
1 Shape defect Poor Defect 4 2 B
Retraction of webbing Retraction of webbing seatbelt restrained
C: 1.42
Material : ISO 4957 - C80U

[Manufacturing Control]: Inpection of Material upon receiving of raw
material 1/batch

4 3 Can occur
3
Test result or
B
C Without measures
COMPONENT : BUFFER DISC

Function rank
[Specification]: A: Spring seat area Ø52.75±0.1
B: Spool bearing area 12.55±0.05mm

Ø 52.75±0.1
Improper Extraction A: 2.512
Proper Extraction and Cannor wear Occupant cannot be
1 and Retraction of Shape Defect Poor Shape 4 2 B
Retraction of webbing seatbelt restrained
webbing 12.55±0.05
B: 2.188

2 ↑ ↑ ↑ Molding defects ↑ ↑ 4 2 B
Material : POM Bluestarcon B130A Nature

3 ↑ ↑ ↑ Wrong material ↑ ↑ 4 2 B

4 3 Can occur
3
Test result or
B
C Without measures
COMPONENT : WS SPRING
Component Mode of Countermeasure
Sl No Severity Occurrence Countermeasures CPK
Function Failure rank
[Specification]: A: 22.5±0.2mm, B: d= 0.18±0.005, C: Di = 4±0.2, D= Total no.of.coils = 21
Assy condition: F1 = 0.024N ±0.01N ( Inspection at component supplier)
100% lock check in house production line
A: 2.897
Improper W/S Occupant cannot be
1 Proper W/S locking Shape defect Poor shape Cannot hold strength 4 2 B B: 1.78
locking restrained
C: 2.85
Material : X10CrNi18-8
2 ↑ ↑ ↑ Wrong material ↑ ↑ 4 2 B As per IS 15140 & ECE R16 - Locking performance check
4 3 Can occur
3
Test result or
B
C Without measures
COMPONENT : PAWL
Component Mode of Countermeasure
Sl No Severity Occurrence Countermeasures CPK
Function Failure rank
[Specification]: A: Pawl teeth profile tolerance 0.2
Occupant caanot be
1 Proper V/S locking Improper V/S locking Shape defect Poor shape Cannot hold Strength 4 2 B A: 1.414
restrained
Profile tolerance 0.2
[Specification]: A: Top Ø 2.91±0.04mm, B: Bottom Ø3.51±0.04mm,C: Height 10.3mm

A: 1.617
2 ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑ B: 1.918
C: 2.048
Ø2.91±0.04mm
Ø3.51±0.04mm
10.3mm

Material : POM HOSTAFORM C13031


4 3 Can occur
3
Test result or
B
C Without measures
COMPONENT : RETURN SPRING

Function rank
[Specification]: A= 0.65mm, B = 6.1,C=25.5±1.5mm
Assy condition: F1 = 7.0N ±1.0N ( Inspection at component supplier)
A: 1.928
B: 1.686
Improper
Proper synchronisation of Occupant cannot be
1 synchronisation of Shape defect Poor shape Cannot hold strength 4 2 B
spool with Base restrained C:1.666
spool with Base
Material : X10CrNi18-8
4 3 Can occur
3
Test result or
B
C Without measures

1.FS1 - RETRACTOR - FMEA - REV001 - 20220927 - Spool - Base 2

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SYSTEM NAME: FS1 RETRACTOR ASSEMBLY

Which is the weakest component in the

Manufacturing Lot information: 1 Lot = 150000, Cavities = 4

vibration High/Low load

[Specification]: A: 88.6±0.2mm ,B: 48.5±0.1mm,C: 19.55mm,D: 17.55mm clearance study

3 ↑ ↑ Shaft's thrust interference Thrust direction out of dimension ↑ ↑ 4 2 B B - 2.760

[Specification]: Spool (reel) Diameter average (φ32.85)

[SPEC] IS15140/ECE R16 static strength Strength study

Material : ADC 12,

[SPEC] IS15140/ECE R16 Corrosion resistance

[Specification]: A: 8.8±0.15mm B: Profile 0.15

drop test High/Low load

[SPEC] IS15140/ECE R16 Corrosion resistance

[Specification]: Gear thickness A: 6.6±0.15mm & B: Gear phase 0.15

[SPEC] IS15140 / ECE R16 static strength

[SPEC] IS15140/ECE R16 Corrosion resistance

Shaft dropping out from the

[SPEC] IS15140 / ECE R16 static strength

[SPEC] IS15140/ECE R16

Severity Rank Definition Frequency of Occurrence Definition

COMPONENT : RETRACTOR BASE

[SPEC] IS15140/ECE R16 static strength

[Specification]: A: Thickness control: 1.5 ±0.06,

Surface treatment: Pre coated steel usage to avoid corrosion

[Specification]: A: Base width: 56.5±0.25mm & B: Angle 90±0.36

[SPEC] IS15140/ECE R16 static strength

Lap and clearance

High/Low load vibration

High speed tensile Drop test

Surface treatment: Pre coated steel usage to avoid corrosion

[SPEC] IS15140/ECE R16 static strength

[Specification]: A: Profile 0.3 In house crimping operation crimping

[SPEC] IS15140/ECE R16 static strength

High/Low load vibration

High speed tensile Drop test

[Specification]: A: Profile 0.1 & B: Profile 0.2

[SPEC] IS15140/ECE R16 static strength

At lock load input

[Specification]: A: Locking side hole diameter: 5.0+0.05/-0 (4 locations)

[SPEC] IS15140/ECE R16 static strength

[Specification]: Suzuki requirement

Severity Rank Definition Frequency of Occurrence Definition

COMPONENT : CONTROL LEVER

[Specification]: A: 9.55±0.1mm B: 12.85±0.1mm

[Specification]: A: Control lever Profile tolerance 0.2 Profile tolerance 0.2

As per IS 15140 & ECE R16 - Locking performance check

[Specification]: A: Profile tolerance 0.2 3X

[Specification]: A: Control lever stopper profile tolerance 0.2

As per IS 15140 & ECE R16 - Locking performance check

Profile tolerance 0.2

[Specification]: Laser welding position: Refer to left figure

[Specification]: Sensor assy Angle check : Refer to Right figure

As per IS 15140 & ECE R16 - Locking performance check

9 ↑ ↑ V/S not assembled properly Defective laser welding ↑ ↑ 4 2 B A: 1.57

[Specification]: A: Profile tolerance on inner diameter 0.1

As per IS 15140 & ECE R16 - Locking performance check

As per IS 15140 & ECE R16 - Locking performance check

[Manufacturing Molding condition management (component supplier)

Severity Rank Definition Frequency of Occurrence Definition

COMPONENT : SENSOR HOUSING

As per IS 15140 & ECE R16 - Locking performance check

V/S activates when tilt or Cannot hold Occupant cannot

[Specification]: Profile tolerance 0.1