Environment Man Method
Competency Inspection
Dirt, metal Cause
filings
Procedures
temperature Dis- Cause
Visual chart
Router
Unorganized work Ergonomics Cause Saw/CNC Cut
Effect:
Failure mode: WRONG LENGTH TUBE AT SAW CUT Regulatory
Violation
Gages Maintenance
Cause Cause Cause
Cutter change Expansion
Accuracy
Capability C of A
Cause Collection method Cause Cause
CNC program
Capability Size
Power
Cause Cause Cause
Process objectives Straightness
Measurement Machine Material
POTENTIAL FAILURE MODES AND EFFECTS WORKSHEET
FMEA Type Level of Detail
Design FMEA Process FMEA System Process Process Step Component / Part
FMEA Number ---> 5637-2007
Telephone #: Email address:
Product / Service Design or Process Responsibility
Identifier --->
345-474494-8475 -------------> Alleak Valves Prepared by ---> Carl Spackler
585-555-1212 test@info.com
End Product(s) / Model FMEA Revision Date
Year(s) --->
RL-1500 Series Valves Other relevant information ---> None Original Date ---> May 29, 2007 ------>
October 2, 2007
Core Team ---> Eric Cartman (FMEA Owner), Kenny (Plant Mfg. rep.), Stan Marsh (engineering rep.), Kyle Brovlowski (quality rep.), Mr. Garrison (purchasing / supplier quality rep.), Mr. Hand (Internal Customer rep.), Chef (Customer rep.)
T
S Fishbone O D R S O D R
Design Item or Process Potential Effect(s) of y Potential Cause(s) / Current Process Controls - Current Process Controls - Responsibility & Target
Potential Failure Mode e Cause c e P Recommended Actions Actions Taken e c e P
Function Requirements Failure p Mechanism(s) of Failure Prevention Detection Completion Date
v Category c t N v c t N
e
saw cutting of tube wrong length cut regulatory violation
9 I wrong setup of saw method
3
setup programs 1st piece verification
3 81
9 I tube not fully held against
back stop
method
5
OJT sensor on back stop with
alarm
2 90
9 I method
0 0 0
9 I operator not trained properly man
4
OJT process verifies
competence through
Training records
4 144
testing
9 I operator tired or
uncomfortable
man
3
regular breaks / table
height can be adjusted
regular supervisor visits
5 135
9 I operator distracted man
4
5 S program regular supervisor visits
5 180
9 I dull saw blade machine
3
PM checks every 1000
cuts
SPC checks every 2 hours
5 135
9 I wrong saw RPM machine
3
setup programs 1st piece verification
3 81
9
I backstop becomes loose machine
7
OJT SPC checks every 2 hours
5 315
Improve clamp on backstop
and add sensor to detect
Stan Marsh - 9/07 clamp improved and
sensor installed 9 3 2 54
movement
9 I tube straightness out of
specification
material
2
Supplier approval Cpk of
1.8
CofA verified at incoming
inspection
7 126
9
I Tube hardness out of
specification
material
7
Supplier approval Cpk of .8 CofA verified at incoming
inspection 7 441
Initiate supplier corrective
action and development to
Mr. Garrison - 9/07 CA completed and Cpk
improved to 1.4 9 3 7 189
improve Cpk
9
I material expansion material
4
temperature controlled in
manufacturing to 68 +/- 5
alarm system on
temperature gage / 2 72
recorder
9 I unorganized work area environment
2
5S Program weekly 5S audits
5 90
9
I excessivesaw cut tablemetal
filings on
dirt, dust or
/
environment
5
OJT regular supervisor visits
5 225
back stop
9
I temperature out of
specification
environment
3
PM checks monthly -
stability of gage
alarm system on
temperature gage / 2 54
recorder
9 I backstop not setup properly - measurement
measurement error 5
OJT 1st piece verification
3 135
I gaging out of calibration measurement calibration frequency
appropriate and methods
SPC checks every 2 hours
9 2
are capable - stability
5 90
studies
I SPC checks not being done measurement OJT regular supervisor visits -
supervisor is required to
9 5
verify SPC checks -
5 225
sampling
Page 1 of 5
Printed: 11/23/2011 FMEA Template Revision: 29-May-07
CONTROL PLAN
Control Plan Category Key Contact Name (Company Name) Date (Orig) Date (Rev) Page
Prototype Pre-Launch Production Eric Cartman 4/30/2001 1/7/2002 1
Control Plan Number Key Contact Phone Customer Engineering Approval (If Req'd) Date (If Req'd)
CP-9001 716-454-0550 N/A N/A
Part Number ECL Supplier / Plant Approval / Date Customer Quality Approval (If Req'd) Date (If Req'd)
9001 A Eric Cartman / Kenny 1/7/2002 N/A N/A
Part Name / Description Other supplier approval by (If Req'd) Other Approval (If Req'd) Date (If req'd)
Cartman Dolls N/A N/A N/A
Supplier / Plant Supplier Code Other Approval Date (If Req'd)
(Company Name) / Rochester, NY N/A N/A
Core team Members
Eric Cartman (FMEA Owner), Kenny (Plant Mfg. rep.), Stan Marsh (engineering rep.), Kyle Brovlowski (quality rep.), Mr. Garrison (purchasing / supplier quality rep.), Mr. Hand (Internal Customer rep.),
Chef (Customer rep.)
Characteristics Controls
Product / Process Evaluation /
Part / Process Name / Machine, Device, Jig, Sample Sample
No. Product Process Special Char. Class. Specification / Measurement Control Method Reaction Plan
Proc # Operation description Tools For Mfg. Size Freq.
Tolerance Technique
30 Saw Cut tube CNC radial cutter 1 Tube Length I 1.050" +/- .010" 0"-6" dial 1 part every SPC control Stop machine, assign
caliper 10 chart cause, adjust machine,
parts inspect next 10 parts
Cutting I Capability > 1.67 Cpk on-going 1 part Every Control chart, If Cpk is < 1.67 or
Cpk study 10 sub-groups of process is out of
parts 5, calculate control - notify
control limits Maintenance Manager
each day for machine
diagnostics, notify
Planner for re-route
and inventory
adjustments
Cutting I Operator training, Monthly all each Evaluations, Notify Human
Router and evaluations Opera month Supervisor resources, adjust
standard work tors witness and competency matrix and
procedures review SPC for develop special training
cause methods
identification
Cutting I RL 1350 CNC CNC RL1350-C All every ME server, J: Notify ME Manager if
program current rev. from CNC progra run drive, only wrong program or can
rev. controller ms current rev. not down load from
Router defines server.
the program #
and revision -
password Set-
up personnel
only
Page 1 of 5 Printed on: 11/23/2011
CONTROL PLAN
Control Plan Category Key Contact Name (Company Name) Date (Orig) Date (Rev) Page
Prototype Pre-Launch Production Eric Cartman 4/30/2001 1/7/2002 1
Control Plan Number Key Contact Phone Customer Engineering Approval (If Req'd) Date (If Req'd)
CP-9001 716-454-0550 N/A N/A
Part Number ECL Supplier / Plant Approval / Date Customer Quality Approval (If Req'd) Date (If Req'd)
9001 A Eric Cartman / Kenny 1/7/2002 N/A N/A
Part Name / Description Other supplier approval by (If Req'd) Other Approval (If Req'd) Date (If req'd)
Cartman Dolls N/A N/A N/A
Supplier / Plant Supplier Code Other Approval Date (If Req'd)
(Company Name) / Rochester, NY N/A N/A
Core team Members
Eric Cartman (FMEA Owner), Kenny (Plant Mfg. rep.), Stan Marsh (engineering rep.), Kyle Brovlowski (quality rep.), Mr. Garrison (purchasing / supplier quality rep.), Mr. Hand (Internal Customer rep.),
Chef (Customer rep.)
Characteristics Controls
Product / Process Evaluation /
Part / Process Name / Machine, Device, Jig, Sample Sample
No. Product Process Special Char. Class. Specification / Measurement Control Method Reaction Plan
Proc # Operation description Tools For Mfg. Size Freq.
Tolerance Technique
Tube Length Environment, I CNC shop CNC shop every Every Maintenance If outside or
material expansion temperature, 70° polar chart shift 4 Manager parameters, stop
+/- 3° temp. recorder hours review Polar machines, perform
and temp. charts, diagnostics on HVAC
controller annotate with system, Notify Planner
initials for re-rout and
inventory adjustments
Tube Length Cutter change I 500 parts, 1.050" Calipers 1part Every Control chart, If trend is detected,
+/- .010" 10 sub-groups of Operator to notify Set-
parts 5, calculate up person and adjust
control limits cutter comp. Inspect 10
each day parts to assure
capability, annotate
control chart
Page 2 of 5 Printed on: 11/23/2011
CONTROL PLAN
Control Plan Category Key Contact Name (Company Name) Date (Orig) Date (Rev) Page
Prototype Pre-Launch Production Eric Cartman 4/30/2001 1/7/2002 1
Control Plan Number Key Contact Phone Customer Engineering Approval (If Req'd) Date (If Req'd)
CP-9001 716-454-0550 N/A N/A
Part Number ECL Supplier / Plant Approval / Date Customer Quality Approval (If Req'd) Date (If Req'd)
9001 A Eric Cartman / Kenny 1/7/2002 N/A N/A
Part Name / Description Other supplier approval by (If Req'd) Other Approval (If Req'd) Date (If req'd)
Cartman Dolls N/A N/A N/A
Supplier / Plant Supplier Code Other Approval Date (If Req'd)
(Company Name) / Rochester, NY N/A N/A
Core team Members
Eric Cartman (FMEA Owner), Kenny (Plant Mfg. rep.), Stan Marsh (engineering rep.), Kyle Brovlowski (quality rep.), Mr. Garrison (purchasing / supplier quality rep.), Mr. Hand (Internal Customer rep.),
Chef (Customer rep.)
Characteristics Controls
Product / Process Evaluation /
Part / Process Name / Machine, Device, Jig, Sample Sample
No. Product Process Special Char. Class. Specification / Measurement Control Method Reaction Plan
Proc # Operation description Tools For Mfg. Size Freq.
Tolerance Technique
Page 3 of 5 Printed on: 11/23/2011