POTENTIAL

FAILURE MODE AND EFFECTS ANALYSIS

Print # Rev. 1 (PROCESS FMEA) FMEA Number: IPF-001
Item: Inners Assembly Process Responsibility: Value Added Dept. Prepared by:
Jeff Stob
Model Year(s)/Vehicle(s) 2009 Key Date Date (Orig.) 8/11/2009
Core Team: Artemio Mora, Jeff Stob, Richard Kimche, Date (Rev.)
Poonam Pavar
C O D
Responsibili Action Results
Process S l Potential c e R.
Proc Potential Potential ty
Function/ Causes(s)/ c Current Process Current Process Controls- t P. Recommended S O D R
ess Failure Effect(s) e a & Target
Require- Mechanism(s) Controls-Prevention Detection Action(s) Actions
# Mode of Failure v s u e N. Completion e c e P
ments of Failure Taken
s r c Date v c t N
1 Material Receipt Damaged Components Unusable Components 7 Damaged at Supplier or in 2 Skip lot inspection per See Flowplan ICF-1 2 28 Receiving clerk will be The receiving
transit Inventory Cycle Flowplan trained to identify freight operators
ICF-1 damage & enter it on the have been
waybill train on this
action.
However,
their training
will be
documented
by 8/21/09

2 Verify Packslip Packslip and physical qty Incorrect part number 4 Supplier has not properly 3 Control with CIP-1 QAR - Receiving Discrepancy 2 24
do not match Incorrect quantity identified part number / qty report
3 WMS assigns Cannot use RF Scanner No label 4 Supplier did not apply bar code 3 Contact Supplier - QAR - Receiving Discrepancy 2 24
internal tracking readable label or label Request bar code label on report
number (tally) damaged in transit future shipments
after scanning
4 Tally Labels
PN, qty, & mfg Apply wrong tally label to Misidentify cartons and 6 Operator did not verify correct 4 ICF-1 Inventory Audit Procedure IAP-1 2 48 When an order is picked, The material
generated
date and cartons / skid skids part number; applied wrong the operator has to scan the handlers
applied to tally label to cartons/skids location, tally number & have been
cartons / skids customer bar code label. If train on this
the tally number & part action.
number do not match, the However,
process does not advance their training
further will be
documented
by 8/21/09

5 Incoming Quality Damaged Components Unusable Components 7 Damaged at Supplier or in 2 Lot inspection per IQC WI See Incoming Inspection Procedure 2 28 Receiving clerk will be The receiving
Inspection transit IIP-1 trained to complete the operators
incoming inspection have been
process, identify freight train on this
damage & enter it on the action.
waybill. Picking associate However,
will be trained to inspect their training
components will be
documented
by 8/21/09

6 Locate Material Place cartons / skids in Scan wrong location, miss- 4 Operator scanned wrong 2 Mislocated Material Inventory Audit Procedure IAP-1 2 16
wrong location locate cartons/skids location bar code Flowplan ICF -1.3.4

7 Order Entry Wrong part / qty entered pick / ship wrong material 6 Automated order entry process 1 ICF-1 , Use Automated 1 6 In the event the part The
(manual process only) unavailable or did not receive Order entry number has never been Operations
automated order entry form produced in Guadalajara an and Program
from customer automatic email will be sent Manager are
to Tecvox and JIT responsible
associates instructing them to review the
to verify the applicable drawings -
component and assembly training
drawings complete
8/14/09

8 Material Pick Pick wrong material - Ship wrong material 8 RF scanner inoperable 1 ICF-1 Use backup RF scanner 2 16
manual pick
9 Bake heads in Not all of the oil is bake The glue will not adhere to 4 The seal may prematurely 2 Work Instructions, Finished Goods Inspection, First 2 16 The production supervisor The training
oven to remove off of the head the head properly come loose from the head Finished Goods and Last article approval will sign off on the first and for to
oil Inspection, First and Last last article approval then complete the
article approval submit the form to the first and last
Operations Manager article
inspection
will be
completed by
8/21/09

10 Cool heads The head is too hot to The associate may 7 The associate would not focus 1 Work Instructions and Time to verify the heads have 1 7
safely handle by an experience discomfort on the process appropriately visual aids cooled before handling
associate when handling the heads

11 Place three Glue is not correctly Too much glue may be 4 Excess glue may be present 2 Work Instructions, Finished Goods Inspection, First 2 16
spots of glue on applied to the head applied to the head on the head Finished Goods and Last article approval
the rim Inspection, First and Last
article approval

12 Place the ring on The ring may not be The assembly may not 8 Associate was distracted or 1 Training program as Finished Goods Inspection, First 1 8 Rotate employees every This is the
the top of the rim function properly been in the same position for documented in HROP-1, and Last article approval two hours responsibility
on head rim too long work instructions, first and of the
correctly last article approval Warehouse
Supervisor -
8/14/09

13 Inspect the inner A defect may not be The assembly may not 8 Associate was distracted or 1 Work Instructions, Finished Goods Inspection, First 1 8 100% safe launch This is the
assembly function properly been in the same position for Finished Goods and Last article approval inspection responsibility
detected too long Inspection, First and Last of the
article approval Warehouse
Supervisor -
8/14/09

Tecvox OEM Solutions

492044056.xls
Confidential
 POTENTIAL
FAILURE MODE AND EFFECTS ANALYSIS
Print # Rev. 1 (PROCESS FMEA) FMEA Number: IPF-001
Item: Inners Assembly Process Responsibility: Value Added Dept. Prepared by:
Jeff Stob
Model Year(s)/Vehicle(s) 2009 Key Date Date (Orig.) 8/11/2009
Core Team: Artemio Mora, Jeff Stob, Richard Kimche, Date (Rev.)
Poonam Pavar
C O D
Responsibili Action Results
Process S l Potential c e R.
Proc Potential Potential ty
Function/ Causes(s)/ c Current Process Current Process Controls- t P. Recommended S O D R
ess Failure Effect(s) e a & Target
Require- Mechanism(s) Controls-Prevention Detection Action(s) Actions
# Mode of Failure v s u e N. Completion e c e P
ments of Failure Taken
s r c Date v c t N
14 Package the The wrong quantity The customer would 4 Associate was distracted or 2 Work Instructions, Finished Goods Inspection, First 2 16
inner assemblies receive the wrong quantity been in the same position for Finished Goods and Last article approval
in shipping
may be placed in a too long Inspection, First and Last
cartons shipping carton article approval

15 Verify Ship Incorrect quantity in ship Cannot complete order. 5 Wrong material placed in 1 Assembly Process Remove material from ship stage 1 5 Only one part number will The
Material : Create stage area Material cannot be shipped shipping stage area Flowplan - APF -1 area be labeled at a time to Warehouse
shipper doc. prevent a labeling error. In Supervisor is
addition, the Program responsible
Manager will complete a to ensure one
random inspection of the part number
out-bound material is labeled at a
time - 8/14/09

Load Truck for Place material on wrong Customer does not receive 6 Operator did not scan / verify 2 Assembly Process Ship correct part number on next 1 12
delivery to end truck correct material correct material Flowplan - APF -1 shipment. Complete internal QAR
user and corrective action
16
Load Truck for Damage material while Forklift driver accidentally 6 Forklift driver did not follow 1 MHEP-1 Ship correct part number on next 2 12
delivery to end loading on truck damages material material handling equipment shipment. Complete internal QAR
user procedure MHEP-1 and corrective action

Tecvox OEM Solutions

492044056.xls
Confidential