Master PFMEA / Lessons Learned

The information contained in this Document is

Commodity: Process - Heat Treating Date (Orig.): 9/27/2015 Future / Current Program Read Across
SQE Lead: Melissa McClive
confidential and proprietary to FCA Inc., and its
affiliates. It is intended to be used solely by suppliers
and contractors who are bound under the Production
SQE Co-Chair: Mahendra Patel Date (Rev.): 2/12/2016 Worksheet:
and MOPAR Purchasing General Terms and
Conditions, or Indirect Materials and Logistics Future / Current Program Read Across SQE Log:
Services Purchasing General Terms and Conditions.
SQE MY / Program Date SQE MY / Program Date

1/12/2017 2:07
3/13/2017 2:07
problem
( ) Model Year & Program:
( )
Process step Requirements
Failure Mode
Cause(s)/of Failure
Issue Source, characteristic to control characteristic requirement Current Process Controls Detection / Prevention and Detailed description of Process Control Does failure mode exist in Action Plan / Comment: [REQUIRED]
noun Effects of Failure
MY / Program, Date verb ( it is just for reference. (hole diameter, boss height, ( tab facing up, material "A", (must be something to be corrected or controlled, Rank (describe the best practice control for this failure mode) design / process? If YES - Provide Action Plan
( e.g.: drill, assemble, machine, bend, (described as the negative outcome of the no guarantee of no more occurrences)
Provide details of the "noun". edge condition, gloss level, 3 screws, smooth surface, 2 requirements)
Yes/No/N/A If NO or N/A - Provide Comment
cure, fasten, paint, etc.)
eg: RHD halogen bulb )
flatness, etc.) plates )
Product:
1) Retain all cut samples. If Safety Characteristics apply,
then follow PS Safety:
a. set-up samples -1 year
PRI# 16-021-01 b. samples after program change 1 year
eCIMS 399549 c. first piece after maintenance 1 year
16 KL d. 6 months of production samples (FCA approval
10/03/2015 /eCIMS required, for deviations)
398191 1) Error Proof (Prevention)_ by product / process / d1. first piece samples of the week 1 year
MY 15 / 16 DS Matches part number and System allows operator to machine / fixture design..discrepant parts cannot be made.
9/14/2014 Induction heat treat Shaft Program release revision Wrong program selected Out of specification heat treat select wrong program [P] 2) 100% NDT automated inspection to detect soft spot or
low surface hardness for safety shield characteristic
3) Frequency of destructive testing: 1 per spindle, per 500
pieces (deviations must be approved by FCA materials
engineering)
4) Hardness checks on diameters should be minimum 4
circumferential interface locations.
5) Reported hardness measurements must be an average
of minimum 3 indents per required location.
6) Microstructure checks need to be in an etched and
polished mount.
7) Microstructure checks required for assembly interface
1) Error Proof (Prevention)_ by product / process / location(s).
Released version for part System allows operator to machine / fixture design..discrepant parts cannot be made.
number is used Operator modified program Out of specification heat treat modify program [P]

Process:
1) Induction Heat Treat Program:
a) identify the start / stop area of each scan speed
location / zone as a critical characteristic in the control plan.
3) MP in-station_ by automatic controls like electronic Lock PLC controls from unauthorized changes.
devices, switches, sensors, etc. that will detect discrepant b) metallurgy lab specification / cut sheet to specify all
Power Within specification Outside of specification Non uniform heat treat Power supply fault
part and automatically lock part in station to prevent further inspection location(s) meet Start/Stop scanning speed areas
processing. and satisfy print requirement for functional areas, each
spindle.
c) Password protect non-operator functions.
2) Update Process Monitoring System with electronic record
of inspections tied to start of production / set-up:
a. quench flow
b. quench concentration
c. coil maintenance, including visual inspection at start
of each shift.
d. quench system (ring/nozzle/tank/filter)
e. coil signature
f. all metallurgy lab inspections
g. any other (detailed) machine maintenance
3) Add to Management review Induction Heat Treat Program
Audit.
4) Lot traceability tied to birth certificate / part identification.
5) Control of the energy or power for each part.
a. A signature monitor for each machine is preferred. A
signature monitor gives the energy unit (voltage, kilowatt,
etc.) vs. time or distance (for scanning systems).
b. An energy monitor or equivalent is acceptable if approved
by the authorized customer representative.
6) The heat treat supplier to have a coil management
system. Coil refers to the heating coil and the quench
plenum.
a. Spare coils for each part shall be available on-site.
b. Coils shall conform to the approved original design.
c. Engineering change approval from the customer is
required whenever the coil design is changed.

Page 1 of 52

Quench system filter canister-
Water System / Quench Flow
stainless steel
Water system equipment
cooling system-corrosion
resistant (per OEM design)
Regular inspection and cleaning induction machine, quench
of the inductor and quench
spray nozzle(s).
Filtration system capable to
filter quench media down to 100
micron size.
Filter canister not stainless
steel.
Water system equipment
cooling system not corrosion or ineffective cooling-
resistant
PM procedures for the
rings & induction coils not
robust
Filtration system not capable
Excessive contamination-Low Not considered in maintenance
or ineffective quench
Excessive contamination-Low
Not considered in maintenance
or initial design
equipment damage
Excessive contamination-Low
or ineffective quench
Excessive contamination-Low Not considered in maintenance
or ineffective quench or initial design
1) Induction Heat Treat Program:
a) identify the start / stop area of each scan speed
location / zone as a critical characteristic in the control plan.
Lock PLC controls from unauthorized changes.
b) metallurgy lab specification / cut sheet to specify all
inspection location(s) meet Start/Stop scanning speed areas
and satisfy print requirement for functional areas, each
spindle.
c) Password protect non-operator functions.
2) Update Process Monitoring System with electronic record
of inspections tied to start of production / set-up:
a. quench flow
b. quench concentration
c. coil maintenance, including visual inspection at start
of each shift.
3) MP in-station_ by automatic controls like electronic d. quench system (ring/nozzle/tank/filter)
devices, switches, sensors, etc. that will detect discrepant e. coil signature
Cycle interruption
part and automatically lock part in station to prevent further f. all metallurgy lab inspections
processing. g. any other (detailed) machine maintenance
3) Add to Management review Induction Heat Treat Program
Audit.
4) Lot traceability tied to birth certificate / part identification.
5) Control of the energy or power for each part.
a. A signature monitor for each machine is preferred. A
signature monitor gives the energy unit (voltage, kilowatt,
etc.) vs. time or distance (for scanning systems).
b. An energy monitor or equivalent is acceptable if approved
6) MP post-station_by operator using variable gauging or in-
by the authorized customer representative.
station through use of attribute gauging (go/no-go), manual
Damaged coil 6) The heat treat supplier to have a coil management
torque check/clicker wrench, color coding, stamping,
system. Coil refers to the heating coil and the quench
marking.
plenum.
a. Spare coils for each part shall be available on-site.
b. Coils shall conform to the approved original design.
c. Engineering change approval from the customer is
required whenever the coil design is changed.
6) MP post-station_by operator using variable gauging or in-
station through use of attribute gauging (go/no-go), manual
Oxide build up on coil
torque check/clicker wrench, color coding, stamping,
marking.
1) Error Proof (Prevention)_ by product / process /
machine / fixture design. Discrepant parts cannot be made.
or initial design
[P]
1) Error Proof (Prevention)_ by product / process /
machine / fixture design..discrepant parts cannot be made.
[P]
4) MP post-station_ by automatic controls like electronic
Quench rings not maintained
devices, switches, sensors, etc. that will detect discrepant
(cleaned from debris) on a
part and automatically lock part in station to prevent further
regular basis.
processing.
1) Error Proof (Prevention)_ by product / process /
machine / fixture design..discrepant parts cannot be made.
[P]
Page 2 of 52

Process parameters
Checked at the beginning of
every shift, tool change, or any
equipment repair. In absence of
process parameter alarms, also
check process parameters at
end of shift or lot (whichever is
the greater frequency).
Load Part into fixture Orientation and location Centered to coil
Out of spec heat treat of the
Less frequent inspections
part
Not centered Out of specification
System allows operator to miss detect error and prevent discrepant part from being made
inspection
Control plan not designed to
meet requirements
System allows operator not to
record inspections
System allows operator to not
load correctly
Damaged fixture
Clamping failure
Worn fixture
Equipment:
2) Error Detection in-station_ by automatic controls that will 1) Use of flow meter and pressure sensor to detect
acceptable flow at each induction coil.
2) Use stainless steel filter canisters / non-corrosive
(e.g.: error proof pins, guide pins, locator pins, anti-
rotational blocks, etc. ).[P] components on Induction line. Filtration system shall be
capable to filter quench media down to 100 micron size.
3) PM procedures to include the induction machine, quench
rings & induction coils, verify cleanliness inside and outside
of components are clean and free of contaminants; per
OEM recommendations.
1) Error Proof (Prevention)_ by product / process /
machine / fixture design..discrepant parts cannot be made.
[P]
2) Error Detection in-station_ by automatic controls that will
detect error and prevent discrepant part from being made
(e.g.: error proof pins, guide pins, locator pins, anti-
rotational blocks, etc. ).[P]
1) Error Proof (Prevention)_ by product / process /
machine / fixture design..discrepant parts cannot be made.
[P]
6) MP post-station_by operator using variable gauging or in-
station through use of attribute gauging (go/no-go), manual
torque check/clicker wrench, color coding, stamping,
marking.
1) Error Proof (Prevention)_ by product / process /
machine / fixture design..discrepant parts cannot be made.
[P]
6) MP post-station_by operator using variable gauging or in-
station through use of attribute gauging (go/no-go), manual
torque check/clicker wrench, color coding, stamping,
marking.
Page 3 of 52
PASTE HERE THE GENERIC PROCESS FLOW DIAGR
S FLOW DIAGRAM
 Master Lessons Learned Read Across
Section: Process Step [ verb - noun]
Section: Requirements [Product Caracteristic to Control ]

Process Step
verb (operation) noun (detail description))
Add grease
Anodize panel
Apply seat track to seat
Assemble ring
Attach Bimetal
Automatic install Tubes
Bend screws
Bond eyelet
Braze Piston
Cast Tire
Chrome tube
Compression mold Sprue
Convey hole
Crack badges
Crimp pipe
Coat End (edge)
Cure bezels
Cut spring, retainer
Degate Piston
Destack material
Die cutt casting
Drill Sunroof trim piece
Electroplate parts
Entry parts
Extrude cover
Fasten tape on PS, A surface
Forge processor
Form track assembly
Grasp locking nut
Harden Sunshade
Hydroform pipe
Hold rear plate
Indentify Sunroof Ring
Injection hole
Install software
Label head rest tube
Laminate
Load
Lock
Machine
Melt
Mix
Mold
Orient
Pack
Paint
Pierce
Place
Precipitation hardening
Press
Print
Program
Progressive stamping
Pyroprocess
Regrind
Remove
Rivet
Sandblast
Screen
Secure
Select
Set
Sew
Smelt
Spin coat
Shot
Size
Soldering
Spray
Stamp
Sub-assemble
Swedge
Tap
Tape
Tumble polish
Trim
Upload
Wash
Weld
Wet out
Work hardening
ned Read Across
Section:
t Caracteristic to Control ] Section:

Requirements
characteristic to control (CTC) characteristic requirement
absorption above lower limit
adhesion below upper limit
align facing down
amount facing up
angle chamfer free of (voids, gas, etc.)
angle position grain type_
arc length Label info complete
balanced Label legibility
bond integrity less than maximun
carburize material type _
casting internal integrity No less than specified
casting shape No more than specified
clean edge to specification
cleanliness correct fixture location
clearance within spec
color
complete
complete program
composition (material)
concentration
content
contiguious (cast)
coverage
circularity
cylindricity
deformation
density
depth (deep)
diameter
dielectric strength
distorsion
eccenticity
effort
engaged
engineering level
etching
elongation
form
form (circularity)
form (cylindricity)
form (flatness)
form (straightness)
filler content
flammability
flatness
fitted
flow rate
flux volume
frequency
full shot
function
fusion (weld)
gravity
hardness
height
hole (drill/tap)
Identification (ID)
joint
Label
length
location
location (position)
location (concentricity)
location (simmetry)
mass
material type
melt flow
mix
movement
opacity
orientation
orientation (parallelism)
orientation (perpendicularity)
orientation (angularity)
pack
part number
permeability
perpendicularity
PH
position
presence
pressure
profile (of a line)
profile (of a surface)
program full set
quantity
retention
radius
ratio
ratio blend
readable
resistivity
rigidity
run out (circular)
run out (total)
seated
shape
size
software level (type)
soldering
solubility
straightness
surface edge
surface finish
surface integrity (casting)
surface shape
superheat casting point
static decay
stick (adhesion)
strength
structure
tapped
temperature
tensile
tension
thickness
time
tone (ink)
torque
traceability
type
type per EBOM
vibration
velocity
viscosity
volatility
volume
volume Resistivity
wall thickness
weight
weld fusion
width

Form:
straightness
flatness
circularity
cylindricity
 Rev. September-2013

Failure Mode
Current Process Controls

Failure Mode Cause(s)/of Failure

negative of CTC something to be fixed
above Other (describe it):
below incomplete work
bubble instruction not followed
burns lack of training
closed process not followed
contacting procedure not followed
contaminated
does not match
excessive
fail to remove
high
improper
incomplete
inconsistence
incorrect
incorrect angle
incorrect flatness
incorrect orienation - radial
incorrect orientation - axial
incorrect type
installed backwards
installed upsidedown
irregular
knit lines
less than
long
low
missaligned
missing
missinstalled
more than
not . . .
not assembled
not clean
not centered
not Contiguous (air gaps/porosity)
not enough
not fully seated
not a full shot
not legible
off location
open
over secured
over torque
poor surfice
porosity
shallow(eg. weld penetration)
sharp
sink
short
too (adjective, eg glossy)
too big
too dark
too far left
too far right
too great
too high
too large
too light
too little
too long
too low
too much
too narrow
too rough
too short
too small
too thick
too thin
too wide
under
under size
under torque
voids
visible defect (cosmetic)
warpage
wrong selection of
 Commodity Process name
..... .....
a/c lines Assembling
air bag control module Casting
air bags Coating
air condition compressor Crimping
air vents/outlets Extruding
alternator Forging
amplifiers Heat treating
antenna Machining
arc welding Metal Forming
axles Milling
ball joints Molding (injection, blow, etc)
batteries Painting
bearings Reworkig
blanks Stamping
blow molding Welding
body side molding
brackets - aluminum
brake booster (actuation)
brake calipers and pads
brake rotors, discs
bumpers
camshaft
carpet & insulation
carpet bonding to various substrates
cluster
clutches
connecting rod
control arms
convertible tops
coolant - recovery; bottle
crankshaft
cylinder block/head - (gsc) gray iron cyl. block
cylinder block/head - (spm) alum. cyl. head
cylinder block/head - hpdc alum. cyl. block
door modules
door panel
ECM (engine cooling module)
e-coating
elec. steering column lock
electronic modules
electronic throttle body
energy absorbers
engine - assembly
engine - camshaft
engine - damper
engine control unit (ecu)
engine restraint module
exhaust
exterior door handles
fascia
fasteners
fem (front end module)
floor console
flywheel
foam
forging
frames
fuel delivery module
fuel filler tube
fuel filter
fuel injection
fuel rail
fuel tank assy
gas props
general stamping
glass
grille
grille - active grille shutters
halfshaft
hard trim
heat shields
hinges & door checks
hood hinge actuator assembly
horn
hoses & tubes - brake/fuel/vapor
hot stamping
HVAC (unit/ctl. head)
I/S door handles
ignition coil
IGNM (ignition node module)
info systems (radio/nav./ blue tooth)
injection molding - plastic
instrument panel
interior switches
jack - scissor type
key fob / passive entry
laser welded blanks
latches
light bars
lighting - fog
lighting - side marker
lighting (ext.)
load floor
locks
machining
manifolds
mechanical controls (shifters/cables)
mechanized convertible roof systems
mirrors - exterior
mirrors - interior
multi layered gasket
nameplates / badges
nut projection welding
O/S door handles
oil pump
overhead consoles
overhead systems
paint
park brakes
PCB
pedal assemblies
pedal box / brake pedal assy
pistons - (aluminum)
plastic - dual shot/rotational molding
plastic - extruded
plastic - insert molded
plating - chrome
power liftgate
power steering oil cooler
projection screw welding
prop shafts
rear view camera
rocker arm - stamped
rubber - foam
rubber hoses
rubber isolation bushings
rubber products / sealing
seat belts
seat frames
seat trim covers
seats
seats - molded foam
seats (trim covers) cut and sew
seats assembly
sensors
sensors - oxygen
shifter knob
shocks/struts
side steps
sonic welding
speakers
spoilers
spot welding
springs
stamped & welded crossmember
stamping - general stamping
stamping - hot stamping
starter
steering gears (mech./eps)
steering column control module
steering columns (mech./eps)
steering knuckles
steering wheels
sun roof
sun visors
suspension - front coil over shock (fcos)
suspension - front module
suspension - rear coil spring
suspension - rear module
suspension - rear shock assembly
suspension bushings
switches - exterior
thermosonic wire bonding
thermostat
throttle body
tie rods
tires
torque
tpm
transmission
trunk
tube bending
turbo chargers
urea tank
valves
viper seat
water pump
wave soldering
weatherstrip - extrusion
wheel - flares
wheel bearing
wheels (cast alum)
wiper motors / systems
wiper spray bottle
wiring
 Current Proccess Controls
Prevention
PM: Preventive Maintenance
 Current Proccess Controls
EMP types (Detection)
1) Error Proof (Prevention)_ by product / process / machine / fixture design..discrepant parts cannot b
2) Error Detection in-station_ by automatic controls that will detect error and pevent discrepant part
3) MP in-station_ by automatic controls like electronic devices, switches, sensors, etc. that will detect
4) MP post-station_ by automatic controls like electronic devices, switches, sensors, etc. that will dete
5) MP: in-station_ by electronic warning audible, visible devices in-station (light, buzzer, sound, alarms
6) MP post-station_by operator using variable gauging or in-station through use of attribute gauging (g
7) Procedural in-station: Failure Mode detection in-station by operator through visual/tactil/audible m
8) Procedural post-station: Failure Mode detection post-station by operator through visual/tactile/aud
9) Procedural: Failure Mode is not easily detected; e.g. Random audits
10) No controls in place: no current process control, cannot detect or is not analyzed.
 CTC: Characteristic to Control
PCs can almost always be described using adjectives and adverbs
PCs are never phrased as verbs (that what a functional requirement is for).
EMP examples EMP examples EMP examples EMP examples
(1) Error Proof (2) Error Proof (3) Mistake Proofing (4) Mistake Proofing

.g.: error proof pins, guide pins, locator pins, anti-rotational blocks, etc. ).[P]
d automatically lock part in station to prevent further processing.
and automatically lock part in station to prevent further processing.
variable gauging or First Part Check, or Set-up gauging.
orque check/clicker wrench, color coding, stamping, marking.
PA or post-station using attribute gauging (go/no-go, manual torque check/clicker wrench).
uble or more Inspections.
requirement is for).
EMP examples EMP examples EMP examples EMP examples
(5) Mistake Proofing (6) Mistake Proofing (7) Procedural (8) Procedural
 EMP examples EMP examples
(9) Procedural (10) No control
 New Master PFMEA Log

21-Mar-13 creation of the new MPFMEA form based on the last 2 audits performed by the #r
25-Jun-13 concurrence by Dave Benedict, Sheri Panonne and Bryan Brook in order to use th
25-Jun-13 no new name assigned to this document, in the mean time it can be "new form" M
25-Jun-13 status change to remove the word "Draft" in the file name.
4-Jul-13 FPA means: First Part Approval.
5-Jul-13 Document updated based on June-2013 audits
8-Jul-13 explain the requirement for the "Detailed description of Detection Control" sectio
26-Jul-13 New product characterisricas added based on 3rd Party Audit on 7/25/2013.
26-Jul-13 Header updated about the sections that include drop down menu (tab: Process st
26-Jul-13 MPFMEA front page: "Process" is deleted, it is included in the column: "B19" (Proc
22-Sep-13 adding process, commodity and row date approval. Library of data updated base
1-Oct-13 removing "effect" column, adding "prevention" column, updatig "process name"
14-Oct-13 adding tab for PFD: "paste here the generic process flow diagram"
udits performed by the #rd Party Auditor
n Brook in order to use the new MPFMEA form for new audits.
me it can be "new form" MPFMEA or "modified" MPFMEA or "drop down" MPFMEA.

Detection Control" section.

Audit on 7/25/2013.
own menu (tab: Process step-Req's-Current PC)
n the column: "B19" (Process Step - verb).
ary of data updated based last 2 audits (August 23 and Sep, 13).
updatig "process name" items, cleaning "commodity" column.
w diagram"