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					                                                                                                      Supplier Standards Manual
                                                                                                Seat Heat Peel and Stick Heater PFMEA
                                                                                                       Chapter 7 Quality Section
                                                                                                       March 2008 Revision 1.0




Document #:                   1444480                                                    0
Program:                      Template - Peel and Stick Heater PFMEA
Model Year:                   N/A
RFQ # / Basis #:              N/A
Back Office Chief / Manager   Deana Borghi
Back Office Lead              Joe Hebda
Program Manager               Robert Hicks
Phase:                        N/A

     ECO #:           Rev:                                        Change Description:   Date:
                       A      Initial Release




b5cd3c55-4c3a-4afc-bd55-c221737d6ba3.xls                                                                                                Page 1 of 7
                                           Supplier Standards Manual
                                     Seat Heat Peel and Stick Heater PFMEA
                                            Chapter 7 Quality Section
                                            March 2008 Revision 1.0

                    CORE PFMEA SHEET - SEAT HEATERS
Item Date           Revisions
  1.    10/282003   Converted Document from MPACT to Excel.
                    Updated with Password Protections, Added Revision Tab, Updated PFMEA Instruction, Created
  2.     2/4/2004   Separate Tabs for Peel N' Stick and Sewn-In Systems.
  3.    9/14/2004   Updated document with Significant and Critical symbols - Sept 04
  4.     9/9/2005   Updated to reflect revised operational procedures & new Design template.




b5cd3c55-4c3a-4afc-bd55-c221737d6ba3.xls                                                              Page 2 of 7
                                      Supplier Standards Manual
                                Seat Heat Peel and Stick Heater PFMEA
                                       Chapter 7 Quality Section
                                       March 2008 Revision 1.0

     Process Failure Mode Effects and Analysis (Heater PFMEA)
     Instructions

                All 2007 model year and beyond programs must utilize Heater Template.


     NOTE: Process FMEA's must be prepared for all programs (components, subassemblies and
     assemblies) where Johnson Controls has full program design responsibility. (Refer to the AIAG
     FMEA Manual and the AIAG APQP and Control Plan manual).




     Instructions for PEEL N' Sticker Heater PFMEA Template :
1.   Process FMEA's are to be prepared using a cross functional team and the AIAG Potential
     Failure Modes and Effects Analysis (FMEA) manual.
     The cross-functional team should include:
     * Advance Manuf. Engineer (Champion)......PFMEA from similar programs, DFM&A input
     * Product Engineer .................................DFA items for similar programs
     * Quality Engineer .........................
2.   Copy Information from the "Heater_Template" into your existing PFMEA.xls file where you
     process the heater elements. Steps 1-5 should be copied into the area where the heater to
     foam operation occurs. The remaining steps should be incorporated into the seat build process
     at the appropriate operational step. (NOTE: REVIEW BOLD TEXT to determine if items
     apply to processing)
3.   Occurrence numbers can be adjusted by the Cost Functional Team based on Customer Plant
     Problems or Warranty Information. These items should be listed in the Recommended Actions
     Column and used to re-calculate the RPN under the "Reaction Results"

4.   Detection numbers can be adjusted by the Cost Function Team based on Controls not listed
     under the Detection/Prevention Columns. These items should be listed in the Recommended
     Actions Column and used to re-calculate the RPN under the "Reaction Results"




b5cd3c55-4c3a-4afc-bd55-c221737d6ba3.xls                                                   Page 3 of 7
                                                                                                                                                                                                                                                                                 Supplier Standards Manual
                                                                                                                                                                                                                                                                           Seat Heat Peel and Stick Heater PFMEA
                                                                                                                                                                                                                                                                                  Chapter 7 Quality Section
                                                                                                                                                                                                                                                                                  March 2008 Revision 1.0




                                                                                                                                        CORE SEAT HEATER P F M E A

                                                                                                                                        FAILURE MODE                  AND EFFECTS ANALYSIS                                                                                                                                                                                                                       Control Plan
                                                                                                                                                                                                                                           FMEA no#:                                                                 Prototype                 Pre-launch                               Production   Key Contact/Phone                                              Date (Orig.)                                                      Date (Rev.)
                                                                                                                                                                                                                                                                                                    Control Plan Number
             Item/Component: PEEL N' STICK HEATERS                                                OEM                                                                                                                                      Prepared by:      CoE Organization
          Model Year/Vehicle:                                                              Key Date:                                                                                                                                                                                                Part Number/Latest Change Level                                                                  Core Team                                                      Customer Engineering Approval/Date (If Req'd)

                    CoreTeam:                                                                                                                                                                                                        FMEA Date (Orig.)
                                                                                                                                                                                                                                  FMEA Date (Last rev.)                                             Part Name/Description                                                                            Supplier/Plant Approval/Date                                   Customer Quality Approval/Date (If Req'd)



                                                                                                                   Potential                           Standard                   Standard                                                                    Action Results
                                                                                                                                                                                                                                                                                                    Supplier/Plant                                             Supplier Code                         Other Approval/Date (If Req'd)                                 Other Approval/Date (If Req'd)
Item     Process Function/                 Potential                     Potential                                 Cause(s)/                            Process                    Process                          Recommended         Responsibility




                                                                                                                                                                                                     DETECT
                                                                                                                                        OCCUR
                                                                                                   CLASS
                                                                                            SEV




                                                                                                                                                                                                              RPN
 #          Requirements                   Failure                    Effect(s) of                              Mechanism(s)                           Controls                   Controls                            Actions             & Target        Actions         S O     D    R.              Part /        Process Name /            Mach, Device,                      Characteristics                               Special                                               Methods
                                            Mode                        Failure                                  of Failure                           Prevention                 Detection                                               Completion       Taken           e c     e    P.             Process                 Operation         Jig, Tools          No.        Product                 Process                   Char.      Product / Process                      Evaluation                        Sample       Control Method Reaction
                                                                                                                                                                                                                                            Date                          v   c   t    N.             Number                     Description      For Mfg.                                                                      Class.    Specification/Tolerance           Measurement Technique                   Size      Freq.               Plan
 1     Get components             wrong parts                  improper heating                                                            a) Lineside racking with
                                                               locations                                                                       designated lanes
                                                                                                           a. Wrong components
                                                                                             5                                           2  b) Labeled containers                                     6       60
                                                                                                           stocked on line
                                                                                                                                             from supplier w/part
                                                                                                                                                  description
                                                                                                           b. picked up from the
                                                                                                                                                plant procedure for part
                                                                                                           floor, another bin, etc
                                                                                                                                         2      handling re. loose parts,                             6       60
                                                                                                           (other than the correct
                                                                                                                                                   operator training
                                                                                                           location)
                                                                                                           c. similar component
                                                                                                           used in the same station             separation of LH & RH
                                                                                                                                         2                                                            6       60
                                                                                                           (picked up the wrong                   seats/ components
                                                                                                           component)
                                                                                                           d. Wrong components in
                                                                                                           the correct shipping
                                                                                                                                         1                                                           10       50
                                                                                                           container (Supplier
                                                                                                           Issue)
                                  Obtain the correct           non-functioning heater
                                  components but not to        or improper heating
                                  the required design          locations                                                                         a) Prohibit opening box
                                  standards                                                                                                        with cutter/ caution
                                                                                                           a. box cutter cut through            label added to packaging   EOL tester - Check
                                                                                             6             element wire/ harness         2       b) returnable packaging Current Draw (Applies        4       48
                                                                                                           when opening box                        c) special designed      to Series System)
                                                                                                                                                  heater packaging (egg-
                                                                                                                                                 crate) to prevent failure




                                                                                                           b. Component picks up
                                                                                                           foreign materials or
                                                                                                                                                      ODS, (Reject
                                                                                                           comes in contact with         1                                                            7       42
                                                                                                                                                      procedures)
                                                                                                           (especially with the
                                                                                                           adhesive tape)


                                                                                                                                                FIFO Procedures utilized
                                                                                                                                                   at facility, Change   100% visual inspection
                                                                                                           c. FIFO is not conducted      1       Management, Material at point of installation to     7       42
                                                                                                                                                 Inventory management       a master sample
                                                                                                                                                       procedures

                                                                                                           d. previously used                         ODS, (Reject
                                                                                                                                         1                                                            7       42
                                                                                                           component is used                          procedures)
                                                                                                           e. carrying by harness                                            EOL tester - Check
                                                                                                                                         1           ODS, training                                    4       24
                                                                                                           (peel & stick heater)                                               Current Draw
                                                                                                                                                 Incoming part racking,
                                                                                                           f. hanging parts to pre-                                          EOL tester - Check
                                                                                                                                         2          Proper material                                   4       48
                                                                                                           stage at station                                                    Current Draw
                                                                                                                                                       container
                                                               Hot Spot in the harness
                                                                                                                                                 a) Prohibit opening box
                                                                                                           a. Box cutter when                      with cutter/ caution
                                                                                                           opening box (If nick is              label added to packaging
                                                                                             9             between module and            1       b) returnable packaging                              7       63
                                                                                                           heater sensor in the                   c) specially designed
                                                                                                           element)                               heater packaging (egg-
                                                                                                                                                 crate) to prevent failure


                                                                                                           b. Dangling harness get               a) plant procedure for
                                                                                                           snagged by equipment,                 part handling re. loose     EOL tester - Check
                                                                                                                                         2                                                            4       72
                                                                                                           tools fixtures causing                         parts                Current Draw
                                                                                                           nick                                   b) equipment design
                                  Wrong sub-assembly           Non-functional heater                       No heater mat on heated
                                                                                                                                                ODS, Operator training
                                  placed on seat (subasm       No heater on seat             6             seat, or heater mat on        2                                                            7       84
                                                                                                                                                      matrix,
                                  out of sequence)                                                         non-heated seat
 2     Align heater pad to foam   Installed off location/      non-symmetrical heating
       pad.                       mis-alignment
                                                                                                           a. ODS elements are not                                           visual inspection for
                                                               difficult to install hog      3                                           3       Operator training matrix,                            7       63
                                                                                                           followed.                                                           notch alignment
                                                               rings

                                                                                                           b. ODS is not clearly
                                                                                                                                                                             visual inspection for
                                                                                                           defined for operator to       3       Operator training matrix,                            7       63
                                                                                                                                                                               notch alignment
                                                                                                           follow
                                                                                                           c. Lack of alignment
                                                                                                           between heater element
                                                                                                                                                Operator training matrix,
                                                                                                           and foam pads                                                     visual inspection for
                                                                                                                                         2       DFA Review, Safety                                   7       42
                                                                                                           (insufficient installation                                          notch alignment
                                                                                                                                                        Sign off
                                                                                                           reference points /
                                                                                                           datums)
                                                               damage to heater wire              HIC
                                                               causing short or hot spot                   a. Wire positioning in
                                                                                                           trench (too much causing
                                                                                                           'bending' effect under
       Only Applies if Elements
                                                                                                           compression, not enough                                           EOL tester- ground
       Cross over Trenches in                                                               10                                      1                ODS, training                                    7       70
                                                                                                           causing strain, or                                                   detection
             local spots.
                                                                                                           positioned such that
                                                                                                           damage can occur during
                                                                                                           hog ring installation)

 3     Remove tape backing from Installed off location/        non-symmetrical heating
       adhesive.                mis-alignment
                                                                                                           a. ODS elements are not                                           visual inspection for
                                                               difficult to install hog      3                                           3       Operator training matrix,                            7       63
                                                                                                           followed.                                                           notch alignment
                                                               rings




                            FBU PFMEA Heater Template / Rev 02 (15-December-2004)                                                                                                                                                                                   file name: b5cd3c55-4c3a-4afc-bd55-c221737d6ba3.xls                                                                                                                                                                                                         Page 4 of 7
                                                                                                                                                                                                                                                                                              Supplier Standards Manual
                                                                                                                                                                                                                                                                                        Seat Heat Peel and Stick Heater PFMEA
                                                                                                                                                                                                                                                                                               Chapter 7 Quality Section
                                                                                                                                                                                                                                                                                               March 2008 Revision 1.0




                                                                                                                                          CORE SEAT HEATER P F M E A

                                                                                                                                          FAILURE MODE                  AND EFFECTS ANALYSIS                                                                                                                                                                                                                                  Control Plan
                                                                                                                                                                                                                                                        FMEA no#:                                                                 Prototype                 Pre-launch                               Production   Key Contact/Phone                                              Date (Orig.)                                                      Date (Rev.)
                                                                                                                                                                                                                                                                                                                 Control Plan Number
             Item/Component: PEEL N' STICK HEATERS                                                 OEM                                                                                                                                                  Prepared by:      CoE Organization
          Model Year/Vehicle:                                                               Key Date:                                                                                                                                                                                                            Part Number/Latest Change Level                                                                  Core Team                                                      Customer Engineering Approval/Date (If Req'd)

                     CoreTeam:                                                                                                                                                                                                                    FMEA Date (Orig.)
                                                                                                                                                                                                                                            FMEA Date (Last rev.)                                                Part Name/Description                                                                            Supplier/Plant Approval/Date                                   Customer Quality Approval/Date (If Req'd)



                                                                                                                    Potential                            Standard                    Standard                                                                              Action Results
                                                                                                                                                                                                                                                                                                                 Supplier/Plant                                             Supplier Code                         Other Approval/Date (If Req'd)                                 Other Approval/Date (If Req'd)
Item     Process Function/                  Potential                     Potential                                 Cause(s)/                             Process                     Process                               Recommended              Responsibility




                                                                                                                                                                                                         DETECT
                                                                                                                                          OCCUR
                                                                                                    CLASS
                                                                                             SEV




                                                                                                                                                                                                                  RPN
 #          Requirements                    Failure                    Effect(s) of                              Mechanism(s)                             Controls                    Controls                                  Actions                & Target        Actions         S O     D    R.              Part /        Process Name /            Mach, Device,                      Characteristics                               Special                                               Methods
                                             Mode                        Failure                                  of Failure                             Prevention                  Detection                                                        Completion       Taken           e c     e    P.             Process                 Operation         Jig, Tools          No.        Product                 Process                   Char.      Product / Process                      Evaluation                        Sample       Control Method Reaction
                                                                                                                                                                                                                                                         Date                          v   c   t    N.             Number                     Description      For Mfg.                                                                      Class.    Specification/Tolerance           Measurement Technique                   Size      Freq.               Plan

                                                                                                            b. ODS is not clearly
                                                                                                                                                                                visual inspection for
                                                                                                            defined for operator to        3       Operator training matrix,                              7       63
                                                                                                                                                                                  notch alignment
                                                                                                            follow
                                                                                                            c. Lack of alignment
                                                                                                            between heater element
                                                                                                                                                  Operator training matrix,
                                                                                                            and foam pads
                                                                                                                                           2       DFA Review, Safety                                     7       42
                                                                                                            (insufficient installation
                                                                                                                                                          Sign off
                                                                                                            reference points /
                                                                                                            datums)
                                                                damage to heater wire              HIC
                                                                causing short or hot spot                   a. Wire positioning in
                                                                                                            trench (too much causing
                                                                                                            'bending' effect under
       Only Applies if Elements
                                                                                                            compression, not enough                                             EOL tester- ground
       Cross over Trenches in                                                                10                                      1                 ODS, training                                      7       70
                                                                                                            causing strain, or                                                     detection
             local spots.
                                                                                                            positioned such that
                                                                                                            damage can occur during
                                                                                                            hog ring installation)

                                   Heat elements not            element moves and may              HIC
                                                                                                            a. Reuse of heater
                                   adhered to the foam          bunch heater elements                                                               ODS, training, reject
                                                                                             10             element (adhesive is one       1                                   visual, seat appearance    7       70
                                   properly                     causing hot spots                                                                       procedure
                                                                                                            time use)

                                                                                                                                                                                                                        Implement a tape
                                                                                                            b. All tape backing not
                                                                                                                                                                                                                        backing design that has   refer to product
                                                                                                            removed or partially           3           ODS, training           visual, seat appearance    7       210                                                                 10 1     7    70
                                                                                                                                                                                                                        pull tabs for the         design template
                                                                                                            removed or torn
                                                                                                                                                                                                                        operator.
                                                                                                            c. Adhesive comes in
                                                                                                            contact with foreign
                                                                                                                                         1 ODS (Reject procedures)                                        7       70
                                                                                                            materials (dust, dirt, oils,
                                                                                                            etc)
                                                                                                            d. Tape to felt adhesive
                                                                                                            joint separates (as
                                                                                                                                         1 Operator training matrix,                                      7       70
                                                                                                            operator removes tape
                                                                                                            backing)
 4     Attach heater pad to foam Installed off location/        non-symmetrical heating
       pad.                      mis-alignment
                                                                                                            a. ODS elements are not                                             visual inspection for
                                                                difficult to install hog      3                                            3       Operator training matrix,                              7       63
                                                                                                            followed.                                                             notch alignment
                                                                rings

                                                                                                            b. ODS is not clearly
                                                                                                                                                   ODS approval procedure,      visual inspection for
                                                                                                            defined for operator to        3                                                              7       63
                                                                                                                                                   Operator training matrix,      notch alignment
                                                                                                            follow
                                                                                                            c. Lack of alignment
                                                                                                            between heater element
                                                                                                                                                  Operator training matrix,
                                                                                                            and foam pads
                                                                                                                                           2       DFA Review, Safety                                     7       42
                                                                                                            (insufficient installation
                                                                                                                                                          Sign off
                                                                                                            reference points /
                                                                                                            datums)
                                                                damage to heater wire              HIC
                                                                causing short or hot spot                   a. Wire positioning in
                                                                                                            trench (too much causing
                                                                                                            'bending' effect under
       Only Applies if Elements
                                                                                                            compression, not enough                                             EOL tester- ground
       Cross over Trenches in                                                                10                                      1                 ODS, training                                      7       70
                                                                                                            causing strain, or                                                     detection
             local spots.
                                                                                                            positioned such that
                                                                                                            damage can occur during
                                                                                                            hog ring installation)

                                   Heat elements not            element moves and may              HIC
                                                                                                            a. Reuse of heater
                                   adhered to the foam          bunch heater elements                                                               ODS, training, reject
                                                                                             10             element (adhesive is one       1                                                              7       70
                                   properly                     causing hot spots                                                                       procedure
                                                                                                            time use)

                                                                                                            b. not firmly pressed
                                                                                                                                           1           ODS, training           visual, seat appearance    7       70
                                                                                                            down to engage adhesive

                                                                                                       c. Adhesive comes in
                                                                                                       contact with foreign                             ODS, (Reject
                                                                                                                                           1                                   visual, seat appearance    7       70
                                                                                                       materials (dust, dirt, oils,                     procedures)
                                                                                                       etc)
                                   Heater element not           wrinkling of element               HIC a. ODS elements are not
                                                                                             10                                            1 Operator training matrix,         visual, seat appearance    7       70
                                   installed flat               causing hot spots                      followed.
                                                                                                       b. ODS is not clearly
                                                                                                       defined for operator to             1 Operator training matrix,         visual, seat appearance    7       70
                                                                                                       follow
                                                                                                       c. Lack of alignment                       Operator training matrix,
                                                                                                                                                                                visual inspection for
                                                                                                       between heater element              1       DFA Review, Safety                                     7       70
                                                                                                                                                                                  notch alignment
                                                                                                       and foam pads                                      Sign off

                                                                                                            d. Foreign object trapped   Operator training matrix,
                                                                                                                                      1                                        visual, seat appearance    7       70
                                                                                                            under heater mat               scrap procedure

                                                                                                            e. Heater mat folds over
                                                                                                            on itself (sticks to itself
                                                                                                                                           1      Operator training matrix     visual, seat appearance    7       70
                                                                                                            once backings are
                                                                                                            removed
 5     Route wire harness          Improper routing             damage to harness,
                                                                                                            a. ODS elements are not
       through foam                                             causing improper heating      6                                     1 Operator training matrix,                visual, seat appearance    7       42
                                                                                                            followed.
                                                                function
                                                                                                            b. ODS is not clearly
                                                                                                            defined for operator to        1 Operator training matrix,         visual, seat appearance    7       42
                                                                                                            follow




                             FBU PFMEA Heater Template / Rev 02 (15-December-2004)                                                                                                                                                                                               file name: b5cd3c55-4c3a-4afc-bd55-c221737d6ba3.xls                                                                                                                                                                                                         Page 5 of 7
                                                                                                                                                                                                                                                                                               Supplier Standards Manual
                                                                                                                                                                                                                                                                                         Seat Heat Peel and Stick Heater PFMEA
                                                                                                                                                                                                                                                                                                Chapter 7 Quality Section
                                                                                                                                                                                                                                                                                                March 2008 Revision 1.0




                                                                                                                                        CORE SEAT HEATER P F M E A

                                                                                                                                        FAILURE MODE                 AND EFFECTS ANALYSIS                                                                                                                                                                                                                                      Control Plan
                                                                                                                                                                                                                                                         FMEA no#:                                                                 Prototype                 Pre-launch                               Production   Key Contact/Phone                                              Date (Orig.)                                                      Date (Rev.)
                                                                                                                                                                                                                                                                                                                  Control Plan Number
             Item/Component: PEEL N' STICK HEATERS                                                 OEM                                                                                                                                                   Prepared by:      CoE Organization
          Model Year/Vehicle:                                                               Key Date:                                                                                                                                                                                                             Part Number/Latest Change Level                                                                  Core Team                                                      Customer Engineering Approval/Date (If Req'd)

                     CoreTeam:                                                                                                                                                                                                                      FMEA Date (Orig.)
                                                                                                                                                                                                                                             FMEA Date (Last rev.)                                                Part Name/Description                                                                            Supplier/Plant Approval/Date                                   Customer Quality Approval/Date (If Req'd)



                                                                                                                   Potential                           Standard                    Standard                                                                                 Action Results
                                                                                                                                                                                                                                                                                                                  Supplier/Plant                                             Supplier Code                         Other Approval/Date (If Req'd)                                 Other Approval/Date (If Req'd)
Item     Process Function/                   Potential                     Potential                               Cause(s)/                            Process                     Process                                  Recommended               Responsibility




                                                                                                                                                                                                          DETECT
                                                                                                                                        OCCUR
                                                                                                    CLASS
                                                                                             SEV




                                                                                                                                                                                                                   RPN
 #          Requirements                     Failure                    Effect(s) of                             Mechanism(s)                          Controls                     Controls                                     Actions                 & Target       Actions         S O     D    R.              Part /        Process Name /            Mach, Device,                      Characteristics                               Special                                               Methods
                                              Mode                        Failure                                 of Failure                          Prevention                   Detection                                                            Completion      Taken           e c     e    P.             Process                 Operation         Jig, Tools          No.        Product                 Process                   Char.      Product / Process                      Evaluation                        Sample       Control Method Reaction
                                                                                                                                                                                                                                                           Date                         v   c   t    N.             Number                     Description      For Mfg.                                                                      Class.    Specification/Tolerance           Measurement Technique                   Size      Freq.               Plan

 6     Convey/ transport s/a        Components not               damage to harness,
       (ONLY APPLIES IF             properly conveyed/           causing improper heating
       FOAM/HEATER                  transported                  function                                   a. Dangling harness
                                                                                                                                                tucking harness into asm EOL tester - Check Amp
       ELEMENT IS NOT                                                                         6             snagging equipment,          2                                                                 4       48
                                                                                                                                                   for transportation             draw
       INSTALLED AT THE                                                                                     tools, fixtures
       SAME STATION AS
       TRIM COVER)
                                                                                                       c. Heater element is
                                                                                                                                                                            EOL tester - Check Amp
                                                                                                       used as "handle" for              2           ODS, training                                         4       48
                                                                                                                                                                                     draw
                                                                                                       carrying
                                                                 bunching of heater                HIC a. Pulling on dangling
                                                                 causing hot spots           10        wire harness during               1           ODS, training           visual, seat appearance       8       80
                                                                                                       conveying
                                                                                                       b. Tape not firmly
                                                                                                       pressed down to engage            1           ODS, training           visual, seat appearance       7       70
                                                                                                       adhesive
 7     Attach trim cover to foam Heater off location/ mis- damage to jumper wire/                  HIC a. Hogring nicks heater
                                 alignment                 heating element causing                     wire (Applies only if                                                  EOL tester- ground
                                                                                             10                                          2           ODS, training                                         4       80
                                                           short or hot spot                           attaching trim cover with                                                 detection
                                                                                                       Hog Rings)
                                                                                                       b. Hog ring is not shot
                                                                                                       through clearance hole            2           ODS, training           visual, seat appearance       8       160
                                                                                                       in heater mat
                                    Heater moves during          bunching of heater                HIC a. Pulling on wire
                                                                                             10                                          1           ODS, training           visual, seat appearance       8       80
                                    assembly                     causing hot spots                     harness
                                                                                                       b. Excessive Finessing
                                                                                                                                         1           ODS, training           visual, seat appearance       8       80
                                                                                                       of the trim cover
                                                                                                       c. Roller Stanchions
         Only Applies if Using                                                                         catch corners/edges of            1           ODS, training           visual, seat appearance       8       80
        Back Stuffer or Cushion                                                                        the heater element
         Roller to attach Trim                                                                         d. Trim covers catches
                 Cover                                                                                 corners/edges of the              1           ODS, training           visual, seat appearance       8       80
                                                                                                       heater element
                                                                                                                                                                                                                         Revise adhesive material
                                                                                                            e. Poor adhesion
                                                                                                                                                                                                                         to meet current design
                                                                                                            between pad and              2           ODS, training           visual, seat appearance       7       140                                  Engineering                    10 1     7    70
                                                                                                                                                                                                                         template pulloff
                                                                                                            Element
                                                                                                                                                                                                                         requirement
 8     Convey/ transport s/a        Components not               damage to harness,                         a. Dangling harness
                                                                                                                                           tucking harness into asm EOL tester - Check Amp
       (ONLY APPLIES IF             properly conveyed/           causing improper heating     6             snagging equipment,          2                                                                 4       48
                                                                                                                                              for transportation             draw
       FOAM/HEATER                  transported                  function                                   tools, fixtures
       ELEMENT/FOAM IS                                                                                      b. Asm is folded or
       NOT INSTALLED AT                                                                                                                  1           ODS, Training                                         7       42
                                                                                                            bunched
       THE SAME STATION                                                                                     c. Heater element is
                                                                                                                                                                            EOL tester - Check Amp
                                                                                                            used as "handle" for         2           ODS, training                                         4       48
                                                                                                                                                                                     draw
                                                                                                            carrying
                                                                 bunching of heater                HIC
                                                                                                            a. Pulling on wire
                                                                 causing hot spots           10                                      1               ODS, training           visual, seat appearance       8       80
                                                                                                            harness during conveying

                                                                                                            b. Asm is folded or
                                                                                                                                         1           ODS, training           visual, seat appearance       8       80
                                                                                                            bunched
 9     Route & secure wire          Improper routing (places     pinched / cut wire
                                                                                                            a. Exposure to hard                 Operator training matrix,
       harness                      harness between hard         harness causing short        6                                          1                                   visual, seat appearance       7       42
                                                                                                            points                                    DFA review
                                    points)                      condition
                                    Not secured (which may       pinched / cut wire
                                                                                                            a. High insertion forces                ODS sheets and          audible, tactile, or visual
                                    place harness in harms       harness causing short        6                                          2                                                                 7       84
                                                                                                            on retaining clips                     Operator Training.               indicator
                                    way over time)               condition

                                                                                                            b. Inadequate clearances 2             DFA Workshops                                           7       84

                                                                                                            c. ODS Elements are
                                                                                                                                         1 Operator training matrix,                                       7       42
                                                                                                            not followed
                                                                                                            d. ODS is not clearly
                                                                                                            defined for operator to      1 Operator training matrix,                                       7       42
                                                                                                            follow
 10    Connect back element to      Not connected                improper functioning
       cushion element (ONLY                                     heater system                              a. ODS elements are not
                                                                                                                                                                EOL tester - Check Amp
       APPLIES IF SYSTEM                                                                      6             followed. (wire routed  1 Operator training matrix,                                            4       24
                                                                                                                                                                draw after full seat travel
       HEATS BOTH BACK                                                                                      improperly)
       AND CUSHION)
                                                                                                            b. ODS is not clearly
                                                                                                                                                                     EOL tester - Check Amp
                                                                                                            defined for operator to      1 Operator training matrix,                                       4       24
                                                                                                                                                                     draw after full seat travel
                                                                                                            follow
                                    Not fully connected          intermittent operation                                                             ODS sheets and          audible, tactile, or visual
                                                                                              5             a. High insertion forces     2                                                                 7       70
                                                                                                                                                   Operator Training.               indicator

                                                                                                            b. Inadequate clearances              DfA Workshops,
                                                                                                                                     2                                                                     7       70
                                                                                                            to complete task                    Manufacturing Reviews

                                                                                                            c. Lack of indication for               ODS sheets and          operator push-pull-push
                                                                                                                                         2                                                                 4       40
                                                                                                            complete engagement                    Operator Training.           connect method

                                                                                                            d. ODS Elements are
                                                                                                                                         1 Operator training matrix,                                       7       35
                                                                                                            not followed
                                                                                                            e. ODS is not clearly
                                                                                                            defined for operator to      1 Operator training matrix,                                       7       35
                                                                                                            follow
 11    Connect to seat wire         Not connected                non-functioning heater
                                                                                                            a. ODS elements are not                             EOL tester - Check Amp
       harness                                                                                6                                     1 Operator training matrix,                                            4       24
                                                                                                            followed.                                           draw after full seat travel

                                                                                                            b. ODS is not clearly
                                                                                                                                                                            EOL tester - Check Amp
                                                                                                            defined for operator to      1 Operator training matrix,                                       4       24
                                                                                                                                                                            draw after full seat travel
                                                                                                            follow
                                    Not fully connected          intermittent operation                                                             ODS sheets and          audible, tactile, or visual
                                                                                              5             a. High insertion forces     2                                                                 7       70
                                                                                                                                                   Operator Training.               indicator

                                                                                                            b. Inadequate clearances              DFA Workshops,
                                                                                                                                         2                                                                 7       70
                                                                                                            to make connection                  Manufacturing Reviews




                              FBU PFMEA Heater Template / Rev 02 (15-December-2004)                                                                                                                                                                                               file name: b5cd3c55-4c3a-4afc-bd55-c221737d6ba3.xls                                                                                                                                                                                                         Page 6 of 7
                                                                                                                                                                                                                                                                                        Supplier Standards Manual
                                                                                                                                                                                                                                                                                  Seat Heat Peel and Stick Heater PFMEA
                                                                                                                                                                                                                                                                                         Chapter 7 Quality Section
                                                                                                                                                                                                                                                                                         March 2008 Revision 1.0




                                                                                                                                       CORE SEAT HEATER P F M E A

                                                                                                                                       FAILURE MODE                  AND EFFECTS ANALYSIS                                                                                                                                                                                                                               Control Plan
                                                                                                                                                                                                                                                  FMEA no#:                                                                 Prototype                 Pre-launch                               Production   Key Contact/Phone                                              Date (Orig.)                                                      Date (Rev.)
                                                                                                                                                                                                                                                                                                           Control Plan Number
             Item/Component: PEEL N' STICK HEATERS                                                OEM                                                                                                                                             Prepared by:      CoE Organization
          Model Year/Vehicle:                                                              Key Date:                                                                                                                                                                                                       Part Number/Latest Change Level                                                                  Core Team                                                      Customer Engineering Approval/Date (If Req'd)

                     CoreTeam:                                                                                                                                                                                                              FMEA Date (Orig.)
                                                                                                                                                                                                                                         FMEA Date (Last rev.)                                             Part Name/Description                                                                            Supplier/Plant Approval/Date                                   Customer Quality Approval/Date (If Req'd)



                                                                                                                  Potential                           Standard                       Standard                                                                        Action Results
                                                                                                                                                                                                                                                                                                           Supplier/Plant                                             Supplier Code                         Other Approval/Date (If Req'd)                                 Other Approval/Date (If Req'd)
Item      Process Function/                   Potential                     Potential                             Cause(s)/                            Process                        Process                              Recommended         Responsibility




                                                                                                                                                                                                            DETECT
                                                                                                                                       OCCUR
                                                                                                   CLASS
                                                                                            SEV




                                                                                                                                                                                                                     RPN
 #          Requirements                      Failure                    Effect(s) of                           Mechanism(s)                           Controls                       Controls                               Actions             & Target        Actions         S O     D    R.              Part /        Process Name /            Mach, Device,                      Characteristics                               Special                                               Methods
                                               Mode                        Failure                               of Failure                           Prevention                     Detection                                                  Completion       Taken           e c     e    P.             Process                 Operation         Jig, Tools          No.        Product                 Process                   Char.      Product / Process                      Evaluation                        Sample       Control Method Reaction
                                                                                                                                                                                                                                                   Date                          v   c   t    N.             Number                     Description      For Mfg.                                                                      Class.    Specification/Tolerance           Measurement Technique                   Size      Freq.               Plan

                                                                                                           c. Lack of indication for               ODS sheets and             operator push-pull-push
                                                                                                                                        2                                                                    4       40
                                                                                                           complete engagement                    Operator Training.              connect method

                                                                                                           d. ODS Elements are
                                                                                                                                        1 Operator training matrix,                                          7       35
                                                                                                           not followed
                                                                                                           e. ODS is not clearly
                                                                                                           defined for operator to      1 Operator training matrix,                                          7       35
                                                                                                           follow
                                     Improperly connected to non-functioning heater                        a. similar connector on
                                                                                                                                                 DFA Workshops,
                                     mating connector                                                      seat harness (Lack of                                               EOL tester- amp draw
                                                                                             6                                          2      Manufacturing Reviews,                                        4       48
                                                                                                           poka-yoke of harness                                                       check
                                                                                                                                                  Design reviews
                                                                                                           connectors
                                                                                                           b. ODS Elements are
                                                                                                                                        1 Operator training matrix,                                          7       42
                                                                                                           not followed
                                                                                                           c. ODS is not clearly
                                                                                                           defined for operator to      1 Operator training matrix,                                          7       42
                                                                                                           follow
 12    Connect to seat wire      Not connected                    non-functioning heater
       harness to Heat Module or (APPLIES ONLY IF
                                                                                                           a. ODS elements are not                             EOL tester - Check Amp
       switch                    HEATER MODULE                                               6                                     1 Operator training matrix,                                               4       24
                                                                                                           followed.                                           draw after full seat travel
                                 IS ASSEMBLED AT
                                 THE JIT)
                                                                                                           b. ODS is not clearly
                                                                                                                                                                    EOL tester - Check Amp
                                                                                                           defined for operator to      1 Operator training matrix,                                          4       24
                                                                                                                                                                    draw after full seat travel
                                                                                                           follow
                                     Not fully connected          intermittent operation
                                     (APPLIES ONLY IF
                                                                                                                                                   ODS sheets and             audible, tactile, or visual
                                     HEATER MODULE                                           5             a. High insertion forces     2                                                                    7       70
                                                                                                                                                  Operator Training.                  indicator
                                     IS ASSEMBLED AT
                                     THE JIT)
                                                                                                           b. Inadequate clearances              DFA Workshops,
                                                                                                                                        2                                                                    7       70
                                                                                                           to make connection                  Manufacturing Reviews

                                                                                                           c. Lack of indication for               ODS sheets and             operator push-pull-push
                                                                                                                                        2                                                                    4       40
                                                                                                           complete engagement                    Operator Training.              connect method

                                                                                                           d. ODS Elements are
                                                                                                                                        1 Operator training matrix,                                          7       35
                                                                                                           not followed
                                                                                                           e. ODS is not clearly
                                                                                                           defined for operator to      1 Operator training matrix,                                          7       35
                                                                                                           follow
                                     Improperly connected to      non-functioning heater                   a. similar connector on
                                     mating connector             and/or disables Heater                   seat harness (Lack of                 DFA Workshops,                EOL tester- amp draw
                                                                                             8                                          2                                                                    4       64
                                     (APPLIES ONLY IF             Module Functions (Over                   poka-yoke of harness                Manufacturing Reviews                  check
                                     HEATER MODULE                Heats)                                   connectors
                                     IS ASSEMBLED AT                                                       b. ODS Elements are
                                     THE JIT, Severity to                                                                               1 Operator training matrix,                                          7       56
                                                                                                           not followed
                                     be confirmed by                                                       c. ODS is not clearly
                                                                                                           defined for operator to      1 Operator training matrix,                                          7       56
                                                                                                           follow
                                     Module is properly           Non-Functioning heater
                                     connected but damaged        system and/or disables                                                  Reject Procedure, Repair             EOL tester- amp draw
                                                                                             8             a. Module is dropped         2                                                                    4       64
                                     by process (APPLIES          Heater Module                                                                  procedure                            check
                                     ONLY IF HEATER IS            Functions (Over Heats)
                                     PART OF HEATER                                                        b. Module comes in
                                     SYSTEM, Severity to                                                                                  Reject Procedure, Repair             EOL tester- amp draw
                                                                                                           contact with a Static        2                                                                    4       64
                                     be confirmed by                                                                                             procedure                            check
                                                                                                           Discharge
                                     Engineering)                                                          c. Module see a Voltage        Reject Procedure, Repair             EOL tester- amp draw
                                                                                                                                        2                                                                    4       64
                                                                                                           Spike                                 procedure                            check
                                                                                                           d. Module see a reverse        Reject Procedure, Repair             EOL tester- amp draw
                                                                                                                                        2                                                                    4       64
                                                                                                           voltage polarity.                     procedure                            check
 13    Function testing              not tested / tested          shipment of a non-                                                                                           warning lights, current
                                                                                             6             a. Equipment failure         2      Operator training matrix                                      2       24
                                     improperly                   functional heated seat                                                                                         draw (amperage)
                                                                                                                                                ODS, training, Reject
                                                                                                           b. Damage to connector                Procedure, Repair
                                                                                                                                        2                                                                    8       96
                                                                                                           during the function test             procedure, pogo pin
                                                                                                                                                    connectors
 14    Transfer Seat to Ship         Transfer                     inoperable heater
                                                                                                                                               seat lift assist to transfer
       Pallet                        Equipment/Method                                                      a. Improper handling of
                                                                                             6                                          1       seat from build line to                                      9       54
                                     damages of heater                                                     seat
                                                                                                                                                          pallet
                                     element/ harness
                                                                                                           b. Lift assist tool is
                                                                                                           placed in location where              DFA Workshops,
                                                                                                                                        1                                                                    8       48
                                                                                                           wire harness / seat                 Manufacturing Reviews
                                                                                                           element is routed




                               FBU PFMEA Heater Template / Rev 02 (15-December-2004)                                                                                                                                                                                       file name: b5cd3c55-4c3a-4afc-bd55-c221737d6ba3.xls                                                                                                                                                                                                         Page 7 of 7

				
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