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JAKARTA PLANT ENGINEERING STANDARD

RELATING STANDARD
JQM-04-02, JQM-07-01,
JQM-07-02, JQM-07-03,
JQM-07-05, JQM-08-01

TITLE

SERIAL No.
APQP EXECUTION

EDITION

JES PP-00
7

DATE

B. General Rules of PFMEA


B.1. Scope
This procedure describes the method of the table and the "failure mode and eff
analysis" (FMEA) required to analyze the forecast of the non conformance occurred in
production process.

B.2. Purpose
To estimate the failure mode occurred in every stage of the process design. Accordingly
prevent the damage by clarifying the important points controlled, or by deciding
characteristics to be controlled in the process design stage. Therefore, the failure mode
initially prevented.

B.3. Time of Implementation


The process FMEA is arranged in the mass production stage by applying the structu
activities, such as shown in the Diagram of Quality Assurance system, and to stud
evaluate from various points of view.

B.4. The Forming Standard


B.4.1. Format
The basic format is shown in Record No. JES PP-001-03. But if the custom
require a format of their own to be used, then it shall be used accordingly.
B.4.2. Forming Points
(1)
To decide the product which applied the FMEA

The implemented products shall be decided concerned with the design sectio
the products decided by the occurrence of the important control, and the specif
products that have different function from the previous one, or according to t
customer's requirements.
If the product has the same objective and is only different in the dimension, t
making of a new one is not necessary. Revision of the old one is sufficient.

(2)

Characteristics

The effect characteristics of the failure mode is decided based on the dama
occurred in the past and the example of the non conformance, by referring to
specified characteristics (important characteristics, characteristics decided by
customer, etc).

No.
REVISE

DATE

DIVISION

DISTRIBUTION

APPROVED

CHECKED

DARD
JES PP-001
7

PAGE

3/28

failure mode and effect


formance occurred in the

s design. Accordingly, to
led, or by deciding the
efore, the failure mode is

y applying the structural


system, and to study /

3. But if the customers


d accordingly.

with the design sections,


control, and the specified
one, or according to the

ent in the dimension, the


d one is sufficient.

d based on the damage


mance, by referring to the
acteristics decided by the

CHECKED

ISSUED

JAKARTA PLANT ENGINEERING STANDARD


RELATING STANDARD
JQM-04-02, JQM-07-01,
JQM-07-02, JQM-07-03,
JQM-07-05, JQM-08-01

TITLE

SERIAL No.
APQP EXECUTION

EDITION

JES PP-00
7

DATE

Any table of quality assurance function determining made by the cooperation w


the design of T-NSK, is based on the above characteristics.
(3)

Implementation steps

If the object product is decided, the Quality Assurance Department shall make t
draft, and evaluation and the confirming of the content shall by the function tea
(or meeting). After being reviewed, it is approved by the Quality Assuran
Manager, and shall be issued.
The distribution targets are the design division and the sections concerned in t
plant. The original document shall be retained and controlled by the Qua
Assurance Department.
(4)

Corrective action

If Risk Priority Number (RPN) is higher than 75, the corrective action shall
done. The Quality Assurance Department shall conduct a meeting with t
sections concerned in the plant. It also shall re examine the control method, a
shall conduct the corrective action to standardize the evaluation result.
The design division of T-NSK can be requested to conduct the evaluation
required.
The actual corrective action is for example, installing the assuring equipment a
the mistake proofing, restricting the supervision to increase the process capabil
to re-examine the assurance system, including improvising machin
modification, all check implementing, etc.
If the corrective action is not completed, assurance shall be implemented bas
on the all check.

(5)

In conducting the process FMEA of ISO/TS system requirements, the man


shall be used as a reference. The implementation order follows the above.

B.4.3. Steps of Table Making


(1)
FMEA Number
FMEA numbering system is follow the rule in JES GDC-DR-001-013
(2)

Item

Enter the name and number of the system, subsystem or component, for wh
the process is being analyzed.
(3)

Process Responsibility

Enter the OEM. Department and group. Also include the supplier name if known

No.
REVISE

DATE

DIVISION

DISTRIBUTION

APPROVED

CHECKED

DARD
JES PP-001
7

PAGE

4/28

e by the cooperation with


s.

epartment shall make the


hall by the function team
y the Quality Assurance

ections concerned in the


ontrolled by the Quality

orrective action shall be


uct a meeting with the
the control method, and
uation result.
onduct the evaluation if

assuring equipment and


se the process capability,
improvising machines,

l be implemented based

equirements, the manual


ollows the above.

DR-001-013

or component, for which

supplier name if known.

CHECKED

ISSUED

JAKARTA PLANT ENGINEERING STANDARD


RELATING STANDARD
JQM-04-02, JQM-07-01,
JQM-07-02, JQM-07-03,
JQM-07-05, JQM-08-01

(4)

TITLE

SERIAL No.
APQP EXECUTION

EDITION

JES PP-00
7

DATE

Prepared By
Enter the name, telephone number and company of the engineer responsible
preparing the FMEA.

(5)

Model Years / Vehicles


Enter the intended model years and vehicle lines that will utilize and / or
affected by the design / process being analyzed (if known).

(6)

Key Date

Enter the initial FMEA due date, which should not exceed the scheduled start
production date.
(7)

FMEA Date
Enter the date of the original FMEA was completed

(8)

Revision Level
Enter the revision number for each FMEA changes (Related document:
Record No. JES GDC-DR-001-013)

(9)

Date
Enter the revision date of the original PFMEA

(10)

Core Team

List the names of the responsible individuals and departments which have t
authority to identify and / or perform tasks.
(11)

Process Function / requirements

Enter a simple description of the process or operation being analyzed (e.


Lathing, Heat Treatment, Grinding, Assembling). Indicate as concisely as possi
the purpose of the process or operation being analyzed.

(12)

Potential failure Mode

Potential failure Mode is defined as the manner in which the process co


potentially fail to meet the process requirements and / or design intent. It is
description of the nonconformance at that specific operation. It can be a cau
associated with a potential failure mode in a subsequent (down stream) operat
or an effect associated with a potential failure in a previous (upstream) operation

Potential failure Mode is defined as the manner in which the process co


potentially fail to meet the process requirements and / or design intent. It is
description of the nonconformance at that specific operation. It can be a cau
associated with a potential failure mode in a subsequent (down stream) operat
or an effect associated with a potential failure in a previous (upstream) operation

(13)

No.
REVISE

Potential Effects of Failure


Potential Effects of Failure are defined as the effects of the failure mode on t
customers.
The customers in this context could be the next operati
subsequent operations or locations.
DATE

DIVISION

DISTRIBUTION

APPROVED

CHECKED

DARD
JES PP-001
7

PAGE

5/28

engineer responsible for

will utilize and / or be


).

ed the scheduled start of

ed document:

artments which have the

n being analyzed (e.g.,


as concisely as possible

which the process could


or design intent. It is a
ation. It can be a cause
(down stream) operation
s (upstream) operation.

which the process could


or design intent. It is a
ation. It can be a cause
(down stream) operation
s (upstream) operation.

the failure mode on the


be the next operation,

CHECKED

ISSUED

JAKARTA PLANT ENGINEERING STANDARD


RELATING STANDARD
JQM-04-02, JQM-07-01,
JQM-07-02, JQM-07-03,
JQM-07-05, JQM-08-01

(14)

TITLE

SERIAL No.
APQP EXECUTION

EDITION

JES PP-00
7

DATE

Severity

Severity is the rank associated with the most serous effect for a given failu
mode. A reduction in severity ranking index can be effected through a desi
change to system, subsystem or component, or a redesign process. Sever
Rank shall refer to Record No. JES PP-001-21. In case of customer requireme
Severity Rank shall refer to Record No. JES PP-001-22.
(15)

Classification

This column may be used to classify any special process characteristics (e.
critical, key, major, significant) for components, subsystems, or systems that m
require additional process controls.
(16)

Potential Causes / Mechanisms of Failure

Potential Cause of Failure is defined as how the failure could occur, described
terms of something that can be corrected or can be controlled.
(17)

Occurrence ( O )

Occurrence is the likelihood that a specific cause/mechanism of failure occ


Preventing or controlling the causes/mechanism of failure through a design
process change is the only way a reduction in the occurrence ranking can
effected. Occurrence Rank shall refer to Record No. JES PP-001-21. In case
customer requirement, Occurrence Rank shall refer to Record No. JES PP-00
22.
(18)

Current Process Controls

Current Process Controls are descriptions of the controls that either prevent to t
extent possible the failure mode from occurring or detect the failure mode shou
it occur. These controls can be process controls such as fixture error-proofin
Statistical Process Control (SPC), or can be post-process evaluation. T
evaluation may occur at the subject operation or at subsequent operations. The
are two types of Process Control / features to consider:

1).

Prevention

Prevent the cause/mechanism of failure or the failure mode from occurrin


or reduce their rate of occurrence

2).

Prevent the cause/mechanism of failure or the failure mode from occurrin


or reduce their rate of occurrence
Detection
Detect the cause/mechanism of failure or the failure mode, and lead
corrective action.

No.
REVISE

DATE

DIVISION

DISTRIBUTION

APPROVED

CHECKED

DARD
JES PP-001
7

PAGE

6/28

effect for a given failure


fected through a design
design process. Severity
of customer requirement,

ess characteristics (e.g.,


ms, or systems that may

could occur, described in


olled.

hanism of failure occur.


ure through a design or
currence ranking can be
S PP-001-21. In case of
Record No. JES PP-001-

that either prevent to the


the failure mode should
as fixture error-proofing,
ocess evaluation. The
quent operations. There

ure mode from occurring,

ure mode from occurring,

ilure mode, and lead to

CHECKED

ISSUED

JAKARTA PLANT ENGINEERING STANDARD


RELATING STANDARD
JQM-04-02, JQM-07-01, JQM07-02, JQM-07-03, JQM-07-05,
JQM-08-01

(19)

TITLE

SERIAL No.
APQP EXECUTION

EDITION

JES PP-00
7

DATE

Detection (D)

Detection is the rank associated with the best detection control listed in t
process control column. In order to achieve a lower ranking, generally t
planned process control has to be improved. Detection Rank shall refer
Record No. JES PP-001-21. In case of customer requirement, Detection Ra
shall refer to Record No. JES PP-001-22.
(20)

Risk Priority Number (RPN)

The Risk Priority Number is the product of Severity (S), Occurrence (O), a
Detection (D) rankings. This value can be used to rank order the concerns in t
process. [A/J] standard is below 75.
RPN = (S) X (O) X (D)
(21)

Recommended Actions

Engineering assessment for preventive/corrective action should be first direct


at high severity, high RPN, and other items designated by the team. The inte
of any recommended action is to reduce rankings in the following ord
Severity, Occurrence, and Detection.
(22)

Responsibility (for the Recommended Action)

Enter the section / department and person responsible for the recommend
action, and the target completion date.
(23)

Actions taken

After an action has been implemented, enter a brief description of the action a
effective date.
(24)

Action Results

After corrective actions have been identified, estimate and record the resulti
occurrence, severity, and detection rankings. Calculate and record the resulti
RPN.
Follow Up

The process responsible engineer is responsible for assuring that all actio
recommended have been implemented or adequately addressed. The FMEA
a living document and should always reflect the latest design level, as well
the latest relevant actions, including those occurring after the start of productio

The process responsible engineer is responsible for assuring that all actio
recommended have been implemented or adequately addressed. The FMEA
a living document and should always reflect the latest design level, as well
the latest relevant actions, including those occurring after the start of productio

No.
REVISE

DATE

DIVISION

DISTRIBUTION

APPROVED

CHECKED

ARD
JES PP-001
7

PAGE

7/28

on control listed in the


ranking, generally the
on Rank shall refer to
ement, Detection Rank

), Occurrence (O), and


rder the concerns in the

should be first directed


by the team. The intent
n the following order:

e for the recommended

ription of the action and

nd record the resulting


and record the resulting

ssuring that all actions


dressed. The FMEA is
design level, as well as
the start of production.

ssuring that all actions


dressed. The FMEA is
design level, as well as
the start of production.

CHECKED

ISSUED

JAKARTA PLANT ENGINEERING STANDARD


RELATING STANDARD
JQM-04-02, JQM-07-01,
JQM-07-02, JQM-07-03,
JQM-07-05, JQM-08-01

TITLE

SERIAL No.
APQP EXECUTION

EDITION
DATE

B.4.4. PFMEA Review


Original FMEA shall be reviewed for condition such as following:
(1)
New Product/Process
(2)
Internal problem
Example for high scrap, In-house abnormal problem, etc.
(3)
Customer Complaint

JES PP-00
7

No.
REVISE

DATE

DIVISION

DISTRIBUTION

APPROVED

CHECKED

DARD
JES PP-001
7

PAGE

8/28

CHECKED

ISSUED