Process Failure Mode and Effects Analysis (PFMEA) Worksheet

Company Name: CLAVOS NACIONALES PFMEA Team: CLAVOS NACIONES FMEA

Code Team Leader: GOMEZ CHONG JAVIER ALDAIR
Part Name(Description): Tornillo Estructural A-325 PFMEA Date: (Original) 12/26/2019
(Revised) GOMEZ CHONG JAVIER ALDAIR

Note: Color code between Process Flow, PFMEA Master & Process Control Plan are guidance to define link between documents.
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Special
Charact
Process Potential Failure Potential Effect(s) of Potential Cause(s) of Occurre Detectio Responsibility and Target
0 Operation / Process Name Requirements Severity eristic Prevention Controls Detection Controls RPN SD SO Recommended Action
Step # Mode Failure Failure nce n Completion Date
Classific
ation

Physical locations established for

Non conforming parts /
Material mixed Rejected part / Don't meet
the client requirements
Material of different
6 specifications placed on
another in the same place.
each type of material in the raw Periodical inventories of the raw
material warehouse and Stickers materials warehouse in
2 3 36 18 12
that contain all the information accordance whit it's stickers of
about the material (Alloy, Temper, identification .
Dimensions, Etc.)

(In base to the COC and the PO of

Wrong identification of
6 2
material
Inspection and review of all the Material)
material received from the supplier Identification printing by BaaN 1 12 6 12
before entering to the system. (Enterprise resource planning
system)

The purchase is made based on Revision of the article in the PO

Purchase raw material out
Alloy or Temper Fissure, crack, breakage 6 2 the article defined in the structure against the one defined in the 3 36 18 12
of specification
different to the due to fatigue, rupture due (MRP) structure
specification to shear, etc.

Verification of the definition of the

Structure (MRP) incorrectly
6 2
loaded
Review and analysis of all
material by filling the checklist in
applicable documentation prior to
the phase of IF1 product 3 36 18 12
the loading of the structure of the
engineering and process and
PN and matching check.
validation of the IQs

Verification of the definition of the

Review and analysis of all the material by filling the checklist in
Wrong definition of raw
6 2 documentation applicable prior to the phase of IF1 product 3 36 18 12
material
Non conforming parts / the industrialization of the PN engineering and process and
Material validated with validation of the IQs
Rejected part / Don't meet
a Incorrect spec
the client requirements

The purchase is made in based on Revision of the article in the PO

Purchase of raw material
6 2 the article defined in the structure against the one defined in the 3 36 18 12
outside of the specified
Material According to the (MRP) structure
Requirements
1 0 SUPPLY OR MATERIAL
(Temper, thickness, alloy, spec,
dimensions, approved supplier)

Raw material with more Raw material supplied by Inspection and review of all
The material can not be Measuring raw material with
material, over 4 the supplier outside 2 material received from the supplier 3 24 12 8
placed in the tooling Quality inspection "QIMR"
dimensioned dimensions before entering to the system.

Less material excess

Raw material with less Raw material supplied by Inspection and review of all
affects the subjection / Measuring raw material with
material, under 4 the supplier outside 2 material received from the supplier 3 24 12 8
The part can not be Quality inspection "QIMR"
dimensioned dimensions before entering to the system.
machining

Raw material supplied by Inspection and review of all

Thickness with more The material can not be Measuring raw material with
4 the supplier outside 2 material received from the supplier 3 24 12 8
material placed in the tooling Quality inspection "QIMR"
dimensions before entering to the system.

The part can not be
Thickness with less
machining / part with lack
material
of material
Raw material supplied by
6 the supplier outside
dimensions
Inspection and review of all
Measuring raw material with
2 material received from the supplier 3 36 18 12
Quality inspection "QIMR"
before entering to the system.

Raw material inspection in the

Non conforming parts / Missing revision of the list The purchase of materials is only reception of the material with the
Approved supplier Rejected part / Don't meet 6 of suppliers approved by 2 done with sources approved by Check List. 2 24 12 12
the client requirements the client (ASL) the client (In base to the COC and the PO of
the Material)

In the reception of the material of Raw material inspection with the

Raw material does not the supplier no material is entered Check List.
The material can not be 1 1 2 2 2
have COC into the system if it does not have (In base to the COC and the PO of
Material without provide / Stop production / its COC the Material)
certificate of Delay on the 2
conformance manufacturing and In the reception of the material of Raw material inspection with the
delivery of the piece The provider did not
the supplier no material is entered Check List.
provide the required 1 1 2 2 2
into the system if it does not have (In base to the COC and the PO of
documentation
its COC the Material)

Evaluation of the specification

Non conforming parts / label of the raw material adhered
Failure to comply with the Inspection check list of Raw
Validation of the Rejected part / Do not to the plate against the
2 10 ANNEALED HEAT TREATMENT Match mtl with WO requirement 3 process of inspection and 3 Material and Second Revision 3 27 9 9
incorrect Raw Material meet the client specification label of the raw
receipt of Raw Material Check List.
requirements material adhered to the production
order,
Comparison of the "Should Be"
Stop production Missing follow-up to the
Tooling with missing KANBAN of the components of the and the "IS" of the tooling. (Base
/Processing delay / Delay 3 delivery procedure / 2 2 12 6 6
components tools on the KANBAN and the Check
in shipment due to rework reception of tooling
list)
All the tools must be delivered by
Inspection and Validation of the
Tooling with less First Part with more Lack validation of the the manufacturer with their
tools at the time of reception VTR
dimension in the material / Rework of the 4 tooling after it is 3 respective dimensional inspection 2 24 8 12
(Validation Tooling Report by
thickness part manufacture report or CMM validating the
CMM machine)
compliance of this.
 All the tools must be delivered by
Tooling with more Lack validation of the the manufacturer with their Inspection and Validation of the
First Part with less
material in the 4 tooling after it is 3 respective dimensional inspection tools at the time of reception VTR 2 24 8 12
material / First part scrap
thickness manufacture report or CMM validating the (Validation Tooling Report)
compliance of this.
Visual Inspection("Set up check
Internal procedure of
list")
manufacturing, maintenance and
Periodic dimensional
6 Incorrect tool maintenance 1 inspection of tooling 2 12 12 6
inspection(dimensional report
PCA-4X-028 (Tooling
against drawing by CMM
Stop production Manufacturing)
machine))
Damage Tooling /Processing delay / Delay
in shipment due to rework Visual Inspection("Set up check
Tooling according to the Technical Internal procedure of
4 30 Supply Tooling list")
Instruction manufacturing, maintenance and
Bad use of the tooling in Periodic dimensional
6 2 inspection of tooling 1 12 6 12
machine inspection(dimensional report
PCA-4X-028 (Tooling
against drawing by CMM
Manufacturing)
machine))

WO or Technical instruction
The equipment assigned to the PN
"IT-7102571H02-REV01" Identification printing by BAAN
2 2 is established from the 2 8 4 4
with wrong revision or (Enterprise resource planning
engineering development phase.
name of tooling system)

Work order and,

Supply tooling with null, All the tools when they are
10 minutes lost due to Technical instruction "IT-
Badly Supplied Tools 2 incorrect or non-readable 1 manufactured are engraved with 8 16 16 2
resupply 7102571H02-REV01" and visual
identification their applicable nomenclature.
aid

Work order and,

Tooling supplied different
2 1
from the one required
Tooling Engraved that contain the
Technical instruction "IT-
correspondent part number name. 8 16 16 2
7102571H02-REV01" and visual
XXXX-01-7102571H02-F2-A
aid

Non conforming parts / Check list of inspection of tooling

Non-compliance with the
Rejected part / Do not Tooling Engraved that contain the against Work order and,
Validation of incorrect process of inspection,
5 30A Tooling Inspection Match Revision of tooling and WO meet the client 3 3 correspondent part number name. Technical instruction "IT- 8 72 24 9
tooling delivery and receipt of
requirements/ 10 minutes XXXX-01-7102571H02-F2-A 7102571H02-REV01" and visual
tooling
lost due to resupply aid

Technical instruction "IT- Technical instruction "IT-

Do not check coordinates
Wrong origin set up First part scrap 6 2 7102571H02-REV01" for take 7102571H02-REV01", visual aid 8 96 48 12
up
origins, and and First Piece Check.

Do not verify tools position

in accordance with
program comments "CNC-
Wrong tools set up F1-7102571H02-REVA-
(Position in tool First part scrap 6 MN00-00", "CNC-F2-
magazine) 7102571H02-REVA-MN00-
00" and Technical
instruction "IT-
7102571H02-REV01"
The sticker id of tool, indicate the
position number correspondent the
Technical instruction "IT-
tool magazine. In addition of the
7102571H02-REV01"
tool dimensional data, in
2 Sticker id of tool, printed after the 8 96 48 12
accordance with the Technical
Zoller validation and First Piece
instruction "IT-7102571H02-
Check.
REV01". Prepared from the tool
room by a Zoller machine.

Operator training to interpret

Set Up check list will be modified
Wrong tools set up Visual aids and Technical Technical instruction "IT-
10 minutes Part Rework/ Transfer of incorrect tool to by adding visual aid, showing the Gabriel Perez Cuevas
(Tool longitude from 5 3 Instructions also Only Team leader 7102571H02-REV01", visual aid 8 120 40 15
First part scrap machine label values critical information to be introduce 06/03/2019
spindle) and qualified personnel perform and First Piece Check.
by operation machine.
the preparation of the machine

Any damaged tool is segregated Visual aid in the operation of

Non functional tools in tool
Set up damage Tools 30 minutes Part Rework 5 2 and discarded or reworked preparation and supply of tools 8 80 40 10
room
according to the case. and First Piece Check.

Tool supplied different

from the one required Incorrect Follow-Up of the Measurement and validation of Tools measured by Zoller machine,
15 minutes Part Rework/
by the Technical 6 Technical instruction steps 1 each of the tools prior to their tool BAAN code/ID method and 3 18 18 6
First part scrap
instruction "IT- "IT-7102571H02-REV01" supply First Piece Check.
7102571H02-REV01"

Improperly measured Periodic calibration of the tool Tools measured by Zoller machine
All set ups, values, tooling's, tools First part scrap 6 Label with incorrect values 1 3 18 18 6
tool measuring machine and First Piece Check.
and programs are according to the
6 40 Machine Set Up
Technical Instruction and Work
Order Mark "Y" axis on tooling as a
visual reference / Adding
Incorrect Follow-Up of the Only Team leader and qualified Technical instruction "IT-
improper positioning / coordinates in technical Gabriel Perez Cuevas
First part scrap 6 Technical instruction steps 3 personnel perform the preparation 7102571H02-REV01", visual aid 8 144 48 18
positioning of tooling instructions , to verify real origin 06/03/2019
"IT-7102571H02-REV01" of the machine and First Piece Check.
position, and adding a zoom in
image on that zone.

Transfer of CAD program Revision of Technical instruction

Technical instruction
"IT-7102571H02-
REV01"
information Incorrect "IT-7102571H02-REV01" in the
First part scrap 6 3 Program check list 6 108 36 18
Technical instruction "IT- industrialization process (IQM
7102571H02-REV01" Block)

Failure to update the latest

Technical instruction
"IT-7102571H02-
REV01"
revision or corresponding
First part scrap 6 revision of the Technical
instruction "IT-
7102571H02-REV01"
Revision of Technical instruction
Industrialization locks to avoid
"IT-7102571H02-REV01" and
2 launching prior to updating 6 72 36 12
visual aid in the industrialization
information
process (IQM Block)

Similarity between family of

CNC program different comparison of the program vs. the CNC Moriserver administration
First part scrap 6 PN with differentiation in 2 3 36 18 12
from the required WO and First Piece Check.
the Dash number

All programs with old versions CNC Moriserver administration

6 Load a previous revision 1 3 18 18 6
become obsolete. and First Piece Check.

CNC with incorrect Validation and revision by Quality

First part scrap
revision Industrialization blocks to avoid instruction "QI-710571H02
OP with old program
6 3 launching prior to updating REV00" blockages 3 54 18 18
revision
information (industrialization) and First Piece
Check.
Stop production for 5
CNC program is not Applicable program not Validation and revision by IQ
minutes to change the 2 2 Industrialization check list 3 12 6 4
available stored in system blockages (industrialization)
CNC program
Review Technical instruction "IT-
Stop production for 30 Failure to comply with the
All elements accordingly with One or more elements 7102571H02-REV01" instructions
7 40A Machine Set Up inspection minutes to begin again the 3 inspection process of fine 3 Check list of set-up. 8 72 24 9
drawing and WO out of specification and Work Order for set up
set up, tuning.
inspection

Not suitable cutting
Vibrated part 10 minutes Part Rework 3 5
conditions
6 Incorrect Programming
6 Wrong tool offset
5 minutes Part Rework/
Gouge part
First part scrap
6 Wrong tool
6 Damaged tool
6 Wrong origin
3 Incorrect Programming
3 Wrong tool offset
Material excess 20 minutes Part Rework
3 Wrong tool
3 Damaged tool
3 Wrong origin
6 Wrong definition of the tool
Incorrect machine
6 3
adjustment
6 Wrong tool
Big holes First part scrap
6 Incorrect Programming
6 Damaged tool
2 Run out of tool
3 Wrong definition of the tool
Incorrect machine
3 3
adjustment
3 Wrong tool
Small hole 5 minutes Part Rework
3 Incorrect Programming
3 Damaged tool
Not suitable cutting
3 5
conditions
4 Wrong CNC program
4 Wrong origin
Badly located hole First part scrap
Displacement between
4 2
operations.
4 Wrong piece placemen
4 Run out of tool
3 Wrong CNC program
Over Thickness 30 minutes Part Rework 3 Wrong origin
3 Wrong tool
3 Damaged tool
Ensure part manufacturing in
8 50 Machining Process 6 Wrong CNC program
accordance with DWG
6 Wrong origin
Under Thickness First part scrap
Tools length and cutting conditions Cutting conditions are controlled
are standard to the different by CNC machine and First Piece 3 45 9 15
operations Check.
Programming is performed about
nominal dimensions and DATUM´s Review in Vericut and First Piece
2 3 36 18 12
as well as the requirements set in Check.
the drawing and 3d model
Each of the tools contains the
label with their actual medications
since they leave the tool room and Tools measured by Zoller machine
3 3 54 18 18
Only Team leader and qualified and First Piece Check.
personnel perform the preparation
of the machine
Measurement and validation of Tools measured by Zoller machine
3 3 54 18 18
each tool prior to supply and First Piece Check.
Any damaged tool is segregated Visual in the operation of
2 and discarded or reworked preparation and supply of tools 8 96 48 12
according to the case. and First Piece Check.
Review Technical instruction "IT- Technical instruction "IT-
2 7102571H02-REV01" instructions 7102571H02-REV01" and First 8 96 48 12
for take origins Piece Check.
Vericut report 17102571H02-
2 Review in Vericut 3 18 9 6
REV01 and First Piece Check.
Each of the tools contains the
label with their actual medications
since they leave the tool room and Tools measured by Zoller machine
3 3 27 9 9
Only Team leader and qualified and First Piece Check.
personnel perform the preparation
of the machine
Measurement and validation of Tools measured by Zoller machine
3 3 27 9 9
each tool prior to supply and First Piece Check.
Any damaged tool is segregated Visual in the operation of
2 and discarded or reworked as preparation and supply of tools 8 48 24 6
appropriate. and First Piece Check.
Review Technical instruction "IT-
Tools measured by Zoller machine
2 7102571H02-REV01" instructions 2 12 6 6
and First Piece Check.
for take origins
Tolerance is reviewed and the best Quality instruction "QI-
2 tool is defined in the definition of 7102571H02 REV00" and First 6 72 36 12
the program Piece Check.
Quality instruction "QI-
Machining process performed at
7102571H02 REV00" and First 6 108 36 18
the average value of the tolerance
Piece Check.
Measurement and validation of Tools measured by Zoller machine
3 3 54 18 18
each tool prior to supply and First Piece Check.
Vericut report 17102571H02-
2 Review in Vericut 3 36 18 12
REV01 and First Piece Check.
Any damaged tool is segregated Visual in the operation of
2 and discarded or reworked preparation and supply of tools 8 96 48 12
according to the case and First Piece Check.
Tools length and cutting conditions
Tools measured by Zoller machine
4 are standard to the different 2 16 4 8
and First Piece Check.
operations
Test of the operation before to
Tolerance is reviewed and the best
2 start the machining process and 8 48 24 6
tool is defined
First Piece Check.
Quality instruction "QI-
Machining process performed at
7102571H02 REV00" and First 6 54 18 9
the average value of the tolerance
Piece Check.
Measurement and validation of Tools measured by Zoller machine
3 3 27 9 9
each tool prior to supply and First Piece Check.
Vericut report 17102571H02-
2 Review in Vericut 3 18 9 6
REV01 and First Piece Check.
Any damaged tool is segregated Visual in the operation of
2 and discarded or reworked preparation and supply of tools 8 48 24 6
according to the case. and First Piece Check.
Tools length and cutting conditions Cutting conditions are controlled
are standard to the different by CNC machine and First Piece 3 45 9 15
operations Check.
Programming is performed about
nominal dimensions and DATUM´s Review CNC program in Vericut
3 1 12 4 12
as well as the requirements set in and First Piece Check.
the drawing and 3d model
Review Technical instruction "IT- Technical instruction "IT-
2 7102571H02-REV01" instructions 7102571H02-REV01" and First 8 64 32 8
for take origins Piece Check.
Use of tooling holes between Same origin for both operations
different operations as position indicated by technical instruction 3 24 12 8
assurance method. and First Piece Check.
Use of tooling holes between
Tooling holes matrix by Poka Yoke
3 different operations as position 3 36 12 12
system and First Piece Check.
assurance method.
Use tools and tool holders in well Tools measured by Zoller machine
2 3 24 12 8
condition. and First Piece Check.
Programming is performed about
nominal dimensions and DATUM´s Review CNC program in Vericut
1 3 9 9 3
as well as the requirements set in and First Piece Check.
the drawing and 3d model
Review Technical instruction "IT- Technical instruction "IT-
2 7102571H02-REV01" instructions 7102571H02-REV01" and First 8 48 24 6
for take origins Piece Check.
Measurement and validation of Tools measured by Zoller machine
3 8 72 24 9
each tool prior to supply and First Piece Check.
Any damaged tool is segregated Visual in the operation of
2 and discarded or reworked preparation and supply of tools 8 48 24 6
according to the case. and First Piece Check.
Programming is performed about
nominal dimensions and DATUM´s Review CNC program in Vericut
3 2 36 12 18
as well as the requirements set in and First Piece Check.
the drawing and 3d model
Adding coordinates in technical
Review Technical instruction "IT- Technical instruction "IT-
instructions , to verify real origin Gabriel Perez Cuevas
3 7102571H02-REV01" and visual 7102571H02-REV01", visual aid 8 144 48 18
position, and adding a zoom in 06/03/2019
aid instructions for take origins and First Piece Check.
image on that zone.
 Under Thickness First part scrap
6 Wrong tool
6 Damaged tool
6 Run out of tool
3 Incorrect Programming
3 Wrong tool
Roughness out of
10 minutes Part Rework
specification
3 Damaged tool
Not suitable cutting
3 5
conditions
3 Wrong origin
3 Wrong tool
Big Radii 5 minutes Part Rework
3 Damaged tool
Not suitable cutting
3 5
conditions
3 Wrong origin
3 Wrong tool
Small Radii First part scrap
3 Damaged tool
Not suitable cutting
3 5
conditions
3 Wrong origin
Angles out of spec First part scrap
3 Bad piece placement
5 Incorrect programming
5 Wrong origin
Shape Profile out of 30 minutes Part Rework/ 5 Wrong tool
spec First part scrap
5 Damaged tool
Not suitable cutting
5 3
conditions
3 Incorrect machine set up
3 Incorrect programming
10 minutes Part Rework/
Flatness out of spec
First part scrap 3 Wrong tool
3 Damaged tool
Not suitable cutting
3 5
conditions
Part Rejected and 24
Part not according with Incorrect Drawing
hours to reprocess the 7 1
drawing measuring
part
9 60 CMM Part according with drawing
Part Rejected and 15
Select incorrect model minutes to load the correct 7 Send an incorrect model
model
2 Incorrect tool for deburring.
10 70 Deburring Part free of sharp Edges Part with sharp edges 10 minutes Part Rework
Measurement and validation of Tools measured by Zoller machine
3 3 54 18 18
each tool prior to supply and First Piece Check.
Any damaged tool is segregated Visual in the operation of
2 and discarded or reworked preparation and supply of tools 8 96 48 12
according to the case. and First Piece Check.
Use tools and tool holders in well Tools measured by Zoller machine
2 3 36 18 12
condition. and First Piece Check.
Quality instruction "QI-
Increase finish times in the
2 7102571H02 REV00" and First 3 18 9 6
program
Piece Check.
Measurement and validation of Tools measured by Zoller machine
3 3 27 9 9
each tool prior to supply and First Piece Check.
Any damaged tool is segregated Visual in the operation of
2 and discarded or reworked preparation and supply of tools 8 48 24 6
according to the case. and First Piece Check.
Tools length and cutting conditions Cutting conditions are controlled
are standard to the different by CNC machine, First Piece 3 45 9 15
operations Check
Review Technical instruction "IT- Technical instruction "IT-
2 7102571H02-REV01" and visual 7102571H02-REV01", visual aid 8 48 24 6
aid for take origins and First Piece Check.
Measurement and validation of Tools measured by Zoller machine
3 3 27 9 9
each tool prior to supply and First Piece Check.
Any damaged tool is segregated Visual in the operation of
2 and discarded or reworked preparation and supply of tools 8 48 24 6
according to the case and First Piece Check.
Tools length and cutting conditions Cutting conditions are controlled
are standard to the different by CNC machine and First Piece 3 45 9 15
operations Check.
Review Technical instruction "IT- Technical instruction "IT-
2 7102571H02-REV01" and visual 7102571H02-REV01", visual aid 8 48 24 6
aid for take origins and First Piece Check.
Measurement and validation of Tools measured by Zoller machine
3 8 72 24 9
each tool prior to supply and First Piece Check.
Any damaged tool is segregated Visual in the operation of
2 and discarded or reworked preparation and supply of tools 8 48 24 6
according to the case and First Piece Check.
Tools length and cutting conditions Cutting conditions are controlled
are standard to the different by CNC machine and First Piece 3 45 9 15
operations Check.
Review Technical instruction "IT- Technical instruction "IT-
2 7102571H02-REV01" and visual 7102571H02-REV01", visual aid 8 48 24 6
aid for take origins and First Piece Check.
Use of tooling holes between
Tooling holes matrix by Poka Yoke
3 different operations as position 8 72 24 9
system, First Piece Check.
assurance method.
Programming is performed about
nominal dimensions and DATUM´s Review program in Vericut and
2 2 20 10 10
as well as the requirements set in CMM evaluation.
the drawing and 3d model
Review Technical instruction "IT- Technical instruction "IT-
2 7102571H02-REV01" and visual 7102571H02-REV01", visual aid 4 40 20 10
aid for take origins and CMM evaluation.
Measurement and validation of Tools measured by Zoller machine
3 3 45 15 15
each tool prior to supply and CMM evaluation.
Any damaged tool is segregated Visual in the operation of
2 and discarded or reworked preparation and supply of tools 3 30 15 10
according to the case and CMM evaluation.
Tools length and cutting conditions Cutting conditions are controlled
are standard to the different by CNC machine and CMM 3 45 15 15
operations evaluation.
Ensure flatness in the first
2 CMM validation 2 12 6 6
machining stage
Programming is performed about
nominal dimensions and DATUM´s Review program in Vericut and
2 2 12 6 6
as well as the requirements set in CMM evaluation.
the drawing and 3d model
Measurement and validation of Tools measured by Zoller machine
3 3 27 9 9
each tool prior to supply and CMM evaluation.
Any damaged tool is segregated Visual in the operation of
2 and discarded or reworked preparation and supply of tools 8 48 24 6
according to the case and CMM evaluation.
Tools length and cutting conditions Cutting conditions are controlled
are standard to the different by CNC machine and CMM 3 45 9 15
operations evaluation.
All part numbers go through the
stage of industrialization before
The CMM machine produces a
they are produced, in which the
dimensional report as a result of
previous revisions of the drawings
the measurement, in which those
are eliminated and all the 2 14 14 7
characteristics that are out of
applicable documentation is
specifications are highlighted in
declared through the BAAN
red.
system in the applicable
document.
All part numbers go through the
stage of industrialization before
The CMM machine produces a
they are produced, in which the
dimensional report as a result of
previous revisions of the drawings
the measurement, in which those
1 and 3D Models are eliminated and 2 14 14 7
characteristics that are out of
all the applicable documentation is
specifications are highlighted in
declared through the BAAN
red.
system in the applicable
document.
Shape inspection , Quality
2 Periodic change of blades instruction "QI-7102571H02 3 12 6 4
REV00" "Item 23"
10 70 Deburring Part free of sharp Edges Part with sharp edges 10 minutes Part Rework
General training for finishing Shape inspection , Quality
Deburring operation
2 5 operators for the compliance of instruction "QI-7102571H02 3 30 6 10
performed Improperly
parts REV00" "Item 23"
Realization of Quality Instruction
Compliance with quality Measures out of First Part Rejected or First Mistakes in quality Revision according to the IQM
11 80 Dimensional Inspection 4 4 according to customer plans, 2 32 8 16
instruction measures specification Part Scrap instruction block industrialization
drawings and specifications.

Incorrect handling of
12 90 Form 3 Full lay out of the part Missing Documentation Part Rejected 4 4 Documents Check List AS9102 Form 3 2 32 8 16
documents

Follow internal procedure DQ1-10-

0008 "INSPECTION OF THE
Test Parameters of Hardness and Indentation on Indentation not defined in THERMAL TREATMENT OF 100% evaluation of the batch
12 90 Hardness and Conductivity conductivity Incorrect zone
Part Scrap 7
the drawing
2
ALUMINIUM ALLOYS THROUGH produced.
2 28 14 14
HARDNESS AND ELECTRIC
CONDUCTIVITY"
Review of the process report- Time
10-100% of product
Process Audit
High Stay Time scraped / 10-100% of 7 Incorrect time programming 2 Automatic Control Time 2 28 14 14
product Reworked
Correct Pre Cleaning
10-100% of product
High Concentration scraped / 10-100% of 7 Wrong adjustment tank 2 Daily concentration sampling Titration Concentration 2 28 14 14
product Reworked
Training of penetrating liquid
inspectors to follow the procedure. Machine programmed for the
7 No caps removed 3 PCA-4X-006 - INSPECCIÓN shipment of the load to the station 1 21 21 21
PENETRANTE (TIPO I, MÉTODO of removal of plugs.
A, FORMA a)

Internal procedure PCA-4X-006

13 100 Penetrant Inspection Automatic Line System / Process "VERIFICATION OF
7 Wrong level in LP tank 3 3 63 28 14
Sensors SUPERFICIAL TREATMENT LINE
Meet Specifications of Penetrant Operation of SEQUENCE" and check list
Inspection according to Internal penetrating liquids
Reprocess part / Crack
procedure performed incorrectly

Internal procedure PCA-4X-006

Automatic Line System / Process
7 Water Temperature 2 "VERIFICATION OF 4 56 28 14
Sensors
SUPERFICIAL TREATMENT LINE
SEQUENCE" and check list

Internal procedure PCA-4X-006

Automatic Line System / Process "VERIFICATION OF
7 Water Pressure 1 4 28 28 7
Sensors SUPERFICIAL TREATMENT LINE
SEQUENCE" and check list

10-100% of product
High Stay Time scraped / 10-100% of
product Reworked
Pre-cleaning
10-100% of product
High Concentration scraped / 10-100% of
product Reworked
10-100% of product
Right level Low Level
Reworked
14 110 Conversion Coating Part Rework / 1 hour lost
Stay Time High Stay Time in Rework the damaged
parts
Part Rework / 1 hour lost
Stay Time Low Stay Time in Rework the damaged
parts
Part Rework
Increased conductivity by
Temperature High Temperature
dissolving salts
10-100% of product
non-uniform color non-uniform color scraped / 10-100% of
product Reworked
15 110A Conversion Coating Inspection
10-100% of product
Uniform coat Dusty coat scraped / 10-100% of
product Reworked
10-100% of product
Reworked/ still 4 hours
lost in Rework the
damaged parts
Parts without marks Incorrect repair marks
10-100% of product
scraped
6 Incorrect time programming
6 Wrong adjustment tank
Level sensor not correct
4 2
working
4 Incorrect time programming
4 Incorrect time programming
Temperature sensor not
4 Review of the process report
correct working
4 Wrong adjustment tank
4 Wrong adjustment tank
4 Repair not performed
7 Excess Material Removal
Review of the process report- Time
2 Automatic Time Control 2 24 12 12
Process Audit
2 Daily concentration sampling Titration Concentration 2 24 12 12
Automatic, PLC with audible Review of the process report-
2 16 8 8
alarm and line stop. Level Audit
1 Automatic Time Control 2 8 8 4
Review of the process report
1 Automatic Time Control 2 8 8 4
Automatic, PLC with audible
2 16 8 8
alarm and line stop.
2
Inspection according to the
2 Daily concentration sampling procedure 2 16 8 8
Inspection according to the
2 Daily concentration sampling procedure 2 16 8 8
Inspection in the next work station
Training of preparation operators
according to the defects catalogue
before painting according to
contained in the procedure PCA-
2 procedure PCA-4X-007 - PAINT, 2 16 8 8
4X-007 - PAINT, INSPECTION OF
INSPECTION OF PAINT AND
PAINT AND ACCELERATED
ACCELERATED CURING
CURING.
Inspection in the next work station
Training of preparation operators
according to the defects catalogue
before painting according to
contained in the procedure PCA-
2 procedure PCA-4X-007 - PAINT, 2 28 14 14
4X-007 - PAINT, INSPECTION OF
INSPECTION OF PAINT AND
PAINT AND ACCELERATED
ACCELERATED CURING
CURING.

Inspection in the next work station

Zones Without Primer
(HOLES, THREADS AND SPECIFIC
16 120 Prepare part to prime
REQUIEREMENTS OF THE
CUSTOMERS)
according to the defects catalogue
Revision of masking of holes contained in the procedure PCA-
3 Without plugs 2 2 12 6 6
according technical instruction 4X-007 - PAINT, INSPECTION OF
PAINT AND ACCELERATED
2 hours lost due to replace CURING.
INCORRECT
MASKING
the stickers and put in the
correct zone. Inspection in the next work station
according to the defects catalogue
contained in the procedure PCA-
3 Without stickers 2 Print Stickers 2 12 6 6
4X-007 - PAINT, INSPECTION OF
PAINT AND ACCELERATED
CURING.

Inspection in the next work station

according to the defects catalogue
contained in the procedure PCA-
3 Incorrect Alodine 2 Traveler indicated type of alodine 2 12 6 6
4X-007 - PAINT, INSPECTION OF
PAINT AND ACCELERATED
2 hours lost due to replace CURING.
Incorrect Electrical
Electrical Bonding the stickers and put in the
Bonding Inspection in the next work station
correct zone.
according to the defects catalogue
contained in the procedure PCA-
3 Without stickers 2 Print Stickers 2 12 6 6
4X-007 - PAINT, INSPECTION OF
PAINT AND ACCELERATED
CURING.

Inspection in the next work station

2 hours lost due to replace
the stickers and put in the
correct zone.
Parts without marks Incorrect repair marks
4 Repair not performed
Training of preparation operators
according to the defects catalogue
before painting according to
contained in the procedure PCA-
2 procedure PCA-4X-007 - PAINT, 2 16 8 8
4X-007 - PAINT, INSPECTION OF
INSPECTION OF PAINT AND
PAINT AND ACCELERATED
ACCELERATED CURING
CURING.
 Parts without marks Incorrect repair marks
Inspection in the next work station
Training of preparation operators
according to the defects catalogue
before painting according to
10-100% of product contained in the procedure PCA-
7 Excess Material Removal 2 procedure PCA-4X-007 - PAINT, 2 28 14 14
scraped. 4X-007 - PAINT, INSPECTION OF
INSPECTION OF PAINT AND
PAINT AND ACCELERATED
ACCELERATED CURING.
CURING.

17 120A Inspect Preparation to prime


Zones Without Primer
(HOLES, THREADS AND SPECIFIC
17 120A Inspect Preparation to prime
REQUIEREMENTS OF THE
CUSTOMERS)
Inspection in the next work station
according to the defects catalogue
Revision of masking of holes contained in the procedure PCA-
3 Without plugs 2 2 12 6 6
according technical instruction 4X-007 - PAINT, INSPECTION OF
PAINT AND ACCELERATED
2 hours lost due to replace CURING.
INCORRECT
MASKING
the stickers and put in the
correct zone. Inspection in the next work station
according to the defects catalogue
contained in the procedure PCA-
3 Without stickers 2 Print Stickers 2 12 6 6
4X-007 - PAINT, INSPECTION OF
PAINT AND ACCELERATED
CURING.

Inspection in the next work station

according to the defects catalogue
contained in the procedure PCA-
3 Incorrect Alodine 2 Traveler indicated type of alodine 2 12 6 6
4X-007 - PAINT, INSPECTION OF
PAINT AND ACCELERATED
2 hours lost due to replace CURING.
Incorrect Electrical
Electrical Bonding the stickers and put in the
Bonding Inspection in the next work station
correct zone.
according to the defects catalogue
contained in the procedure PCA-
3 Without stickers 2 Print Stickers 2 12 6 6
4X-007 - PAINT, INSPECTION OF
PAINT AND ACCELERATED
CURING.

Inspection in the next work station

Without Contamination
according to the defects catalogue
Part Rework / 6 hours lost
Incorrect Cleaning contained in the procedure PCA-
Dirty Parts due to rework 3 Air blow before priming 1 9 3 9
Previous Paint 4X-007 - PAINT, INSPECTION OF
PAINT AND ACCELERATED
3 CURING.

Inspection in the next work station

according to the defects catalogue
Part Rework / 6 hours lost
Pre-fabrication Painting review/ contained in the procedure PCA-
Color Incorrect Paint due to rework 3 Incorrect documentation 3 1 9 3 9
18 130 Prime Part Experience of the painter 4X-007 - PAINT, INSPECTION OF
PAINT AND ACCELERATED
CURING.
Part Rework / 6 hours lost
THICKNESS OUT OF Incorrect application Wet paint thickness test with test
WET THICKNESS due to rework 3 3 Wet paint thickness gauge 2 18 6 9
THE RANGE technique pieces before painting the parts

Training of painters to follow the Painting Inspection according to

Part Rework / 3 hours lost
Incorrect application procedure PCA-4X-007 - PAINT, procedure PCA-4X-007 - PAINT,
Total Paint Coverage Unpainted Areas due to rework 3 2 2 12 6 6
technique INSPECTION OF PAINT AND INSPECTION OF PAINT AND
ACCELERATED CURING ACCELERATED CURING
Training of painters to follow the
Part Rework Non-receptive surface to
LACK OF procedure PCA-4X-007 - PAINT,
Paint adhesion Break Off Painting 3 paint application 2 Receptive Area solvent test 2 12 6 6
ADHERENCE INSPECTION OF PAINT AND
6 hours lost due to rework (Cleaning)
19 130A Inspect Prime on Part ACCELERATED CURING
Part Rework, Remove
Paint application (flow, Thickness check per EDDY
Dry Thickness Thickness out of range prime, still 6 hours due to 3 5 Wet thickness Check 1 15 3 15
pressure) CUREENT
work
Evaluation of the identification and
Part Rework Not programming Set machine in Stop mode when it
3 2 registration in the technical 2 12 6 6
Illegible ID automatic cleaning is not in use
instruction of treatments.
Training to all the operative
20 140 Identification Identification Incorrect ID Part Rework personnel of the painting process
Implementation of a checklist for Allan Albarran / Jose Luis Jimenez
Material Mix , Validate Excess of material in the in the follow-up of the procedure. Quality gate inspection, Final
3 5 8 120 24 15 tanks for material entry and exit
incorrect material for the rack waiting for ID PCA-4X-007 - PAINT, Inspection line.
audits. 20/06/2019
correct part number INSPECTION OF PAINT AND
ACCELERATED CURING

Missing List of
22 190 Form 3 Full lay out of the part Missing Documentation Part Rejected 4
Documentation
4 Documents Check List Documents Check List 2 32 8 16

Technical Instruction and operator

training to follow-up the procedure
Part damaged, Wrong type of packaging
21 150 Certify and packaging Protect Parts against damage
scratches, marks, etc.
4
material
2 ILO-4X-001 MATERIAL Warehouse Inspection 2 16 8 8
Part Rework HANDLING AND PACKAGING
PROCESS.
FMEA RISK TABLES
SEVERITY RISK TABLE
Category Criteria: Severity of Effect Category
Rank
(Product) (Effect on Product) (Process)

Potential failure mode affects safe vehicle

operation and/or involves noncompliance with 10
Safety and/or government regulation without warning Safety and/or
regulatory regulatory
compliance Potential failure mode affects safe vehicle compliance
operation and/or involves noncompliance with 9
government regulation with warning
Primary Loss of primary function (vehicle inoperable, does
8 Major disruption
function not affect safe vehicle operation)

Degradation of primary function (vehicle Significant

Essential 7
operable, but at reduced level of performance) disruption

Secondary Loss of secondary function (vehicle operable, but

6
function comfort / convenience functions inoperable)
Rework out of
Degradation of secondary function (vehicle station
Convenient operable, but comfort / convenience functions at 5
reduced level of performance)
Appearance or audible noise, vehicle operable,
item does not conform. Defect noticed by most 4
customers (> 75%) Rework in
Appearance or audible noise, vehicle operable, station
Annoyance item does not conform. Defect noticed by many 3
customers (50%)
Appearance or audible noise, vehicle operable,
Minor
item does not conform. Defect noticed by 2
disruption
discriminating customers (< 25%)
 No effect No discernible effect 1 No effect

DETECTION RISK TABLE

Opportunity for PFMEA Criteria: Likelihood of
Rank
Detection Likelihood of detection by process control Detection

No detection No current process control; cannot detect or is

10 Almost impossible
opportunity not analyzed
Not likely to detect Failure Mode and/or error (cause) is not easily
9 Very remote
at any stage detected (e.g. random audits)
Problem detection Failure Mode detection post-processing by
8 Remote
post processing operator through visual/tactile/audible means
Failure Mode detection in station by operator
through visual/tactile/audible means or post-
Problem detection
processing through use of attribute gauging 7 Very low
at source
(go/no go, manual torque check/clicker wrench,
etc)
Failure Mode detection post-processing by
operator through the use of variable gauging or
Problem detection
in-station by operator through use of attribute 6 Low
post processing
gauging (go/no go, manual torque check/clicker
wrench, etc)

Failure Mode or Error (cause) detection in-station

by operator through the use of variable gauging,
Problem detection or by automated controls in-station that will detect
5 Moderate
at source discrepant part and notify operator (light, buzzer,
etc.) Gauging performed on setup and first-piece
check (for setup causes only)
 Failure Mode detection post-processing by
Problem detection
automated controls that will detect discrepant part 4 Moderately high
post processing
and lock part to prevent further processing
Failure Mode detection in-station by automated
Problem detection controls that will detect discrepant part and
3 High
at source automatically lock part in station to prevent
further processing
Error detection Error (cause) detection in station by automated
and/or Problem controls that will detect error and prevent 2 Very high
prevention discrepant part from being made
Error (cause) prevention as a result of fixture
Detection not design, machine design or part design.
applicable; error Discrepant parts cannot be made because item 1 Almost certain
prevention has been error-proofed by process/product
design.
TABLE OCCURRENCE RISK TABLE
Criteria: Severity of Effect
Likelihood of Failure Time-based Scale Event-based Scale
(Effect on Process)

May endanger operator (machine or assembly) Very High

1 occurrence / shift Cpk < 0.33
without warning Failure is almost inevitable

High
May endanger operator (machine or assembly)
Failures occur almost 1 occurrence / day Cpk » 0.33
with warning
as often as not
100% of product may have to be scrapped. Line High
1 per 2-3 days Cpk » 0.67
shutdown or stop ship Repeated failures
A portion of the production rue may have to be High
scrapped. Deviation from primary process; Failures occur 1 per week Cpk » 0.83
decreased line speed or added manpower often
100% of production run may have to be reworked Moderate High
1 per 2 weeks Cpk » 1.00
off line and accepted Frequent failures

A portion of the production run may have to be Moderate

1 per month Cpk » 1.17
reworked off line and accepted Occasional failures

100% of production run may have to be reworked Moderate Low

1 per quarter Cpk » 1.33
in station before it is processed Infrequent failures

A portion of the production run may have to be Low

1 per half-year Cpk » 1.67
reworked in station before it is processed Relatively few failures

Low
Slight inconvenience to process, operation or
Failures are few and far 1 per year Cpk » 2.00
operator
between
 Very Low
Failure is eliminated
No discernible effect <1 per year Cpk > 2.00
through prevention
controls
E RISK TABLE
Criteria: Occurrence of
cause - PFMEA
Rank
(incidents per 1000
items / vehicles)

³ 100 per thousand

10
>/= 1 in 10

50 per thousand
9
1 in 20

20 per thousand
8
1 in 50

10 per thousand
7
1 in 100

2 per thousand
6
1 in 500

0.5 per thousand

5
1 in 2 000

0.1 per thousand

4
1 in 10 000

0.01 per thousand

3
1 in 100 000

£ 0.001 per thousand

2
1 in 1 000 000
 Failure is eliminated
1
through preventive control