WD71A

FAILURE MODE EFFECT ANALYSIS - DESIGN / PROCESS

FMEA NUMBER

SHEET OF

PART OR ASSEMBLY NAME:-SUPPLIERS:-

PART OR ASSEMBLY No:-

DRAWING ISSUE:-

AMMENDMENTS12345678910

DATE

FMEA COMMITTEE:-

FMEA APPROVED:-DATE:-

NAME:-SIGNATURE

ITEM / PART No
NAME
ISSUE / FUNCTION
OR
PROCESS / FAILURE
MODE / CAUSE OF FAILURE / EFFECT OF FAILURE / CURRENT
CONTROLS / CURRENT STATUS / RECOMMENDED
CORRECTIVE
ACTION / ACTION
BY / ACTION
TAKEN / REVISED STATUS
OCC / SEV / DET / RPN / OCC / SEV / DET / RPN
Goods In / Incorrect Part / Supplier / Return to Supplier / Visual Inspection / 2 / 7 / 4 / 56
Dimensionally Incorrect / Supplier / Return to Supplier / Gauge Inspection / 3 / 7 / 3 / 63
No C of C / Supplier / Return to Supplier / Visual Inspection / 4 / 3 / 2 / 24
Contamination / Supplier / Return to Supplier / Visual Inspection / 2 / 3 / 4 / 24
Incorrect Quantity / Supplier / Return to Supplier / Gauge Inspection / 2 / 3 / 3 / 18
Damaged / Supplier / Return to Supplier / Visual Inspection / 3 / 7 / 4 / 84
Identification / Supplier Control / Incorrect Parts
Supplied / Visual Inspection / 2 / 3 / 4 / 24
Tube / Goods In / Oversize / Suppler Control / Return to Supplier / Gauge Inspection / 4 / 7 / 3 / 84
Undersize / Supplier Control / Return to Supplier / Gauge Inspection / 4 / 7 / 3 / 84
Wall Thickness / Supplier Control / Return to Supplier / Gauge Inspection / 4 / 7 / 3 / 84
Score Lines / Supplier Control / Return to Supplier / Visual Inspection / 3 / 7 / 4 / 84
Tool Marks / Supplier Control / Return to Supplier / Visual Inspection / 3 / 7 / 4 / 84
Handling Damage / Poor Handling / Unfit for Function / Visual Inspection / 3 / 7 / 4 / 84
Identification / Incorrect Labelling / Misuse of
Material / Visual Inspection / 2 / 3 / 4 / 24
Incorrect Specification / Supplier Control / Return to Supplier / Visual Inspection / 2 / 8 / 5 / 80

FAILURE MODE & EFFECTS ANALYSIS – DESIGN / PROCESS

( CONTINUATION SHEET )

FMEA No

SHEET OF

ITEM / PART No
NAME
ISSUE / FUNCTION
OR
PROCESS / FAILURE
MODE / CAUSE OF
FAILURE / EFFECT OF FAILURE / CURRENT
CONTROLS / CURRENT STATUS / RECOMMENDED
CORRECTIVE
ACTION / ACTION
BY / ACTION
TAKEN / REVISED STATUS
OCC / SEV / DET / RPN / OCC / SEV / DET / RPN
Tube / Cut / Over length / Machine Setting / Unfit for Function / Inspection
Using gauges / 4 / 7 / 3 / 84
Under Length / Machine Setting / Unfit for Function / Inspection
Using gauges / 4 / 7 / 3 / 84
Incorrect Material
Selection / Operator Error / Unfit for Function / Inspection / 2 / 8 / 4 / 64
Damage by Saw / Tool Setting / Unfit for Function / Inspection
Procedure / 3 / 7 / 4 / 84
Excessive Cut
Burr / Worn Blade / Detrimental to
End Form / Visual
Inspection / 4 / 4 / 4 / 64
Out of Shape / Over Clamping / Unfit for Function / Visual
Inspection / 2 / 7 / 4 / 56
Identification / Operator Error / Incorrect Parts
Supplied / Visual
Inspection / 3 / 3 / 4 / 36
Tube / De - Burr / Excessive De - Burr / Excessive Saw Burrs / Detrimental to
End Form / Visual
Inspection / 3 / 4 / 4 / 48
Incorrect Setting / Detrimental to
End Form / Visual
Inspection / 3 / 4 / 4 / 48
Insufficient De - Burr / Incorrect Setting / Detrimental to
End Form / Visual
Inspection / 3 / 4 / 4 / 48
Damage / Machine Setting / Unfit for Function / Visual
Inspection / 3 / 4 / 4 / 48
Handling / Unfit for Function / Visual
Inspection / 3 / 4 / 4 / 48
Identification / Operator Error / Incorrect Parts
Supplied / Visual
Inspection / 3 / 3 / 4 / 36
Tube / Hot Wash
De-Grease / Damage / Bad Loading / Unfit for Function / Visual
Inspection / 2 / 7 / 4 / 56
Not clean / Operator Error / Visually Unacceptable / Visual
Inspection / 3 / 2 / 4 / 24
Incorrect Solution / Visually
Unacceptable / Visual
Inspection / 2 / 2 / 4 / 16
Identification / Operator Error / Incorrect Parts
Supplied / Visual
Inspection / 3 / 3 / 4 / 36

FAILURE MODE & EFFECTS ANALYSIS – DESIGN / PROCESS

( CONTINUATION SHEET )

FMEA No

SHEET OF

ITEM / PART No
NAME
ISSUE / FUNCTION
OR
PROCESS / FAILURE
MODE / CAUSE OF
FAILURE / EFFECT OF FAILURE / CURRENT
CONTROLS / CURRENT STATUS / RECOMMENDED
CORRECTIVE
ACTION / ACTION
BY / ACTION
TAKEN / REVISED STATUS
OCC / SEV / DET / RPN / OCC / SEV / DET / RPN
Tube / Form End A
Using WET / Dimensionally Incorrect / Incorrect Setting / Unfit for Function / Setting Sheet
Gauge Inspection / 4 / 8 / 3 / 96
Incorrect
Tool Selection / Unfit for Function / Setting Sheet
Gauge Inspection / 4 / 8 / 3 / 96
Contamination / Surface Impregnation / Unfit for Function / Visual
Inspection / 3 / 7 / 4 / 84
Handling / Unfit for Function / Operator Training / 3 / 7 / 4 / 84
Damage / Tooling / Unfit for Function / Maintenance Sheet / 3 / 7 / 4 / 84
Operator Error / Unfit for Function / Operator Training / 3 / 7 / 4 / 84
Identification / Operator Error / Incorrect Parts
Supplied / Visual
Inspection / 3 / 3 / 4 / 36
Tube / Bend X 1
Using Tool set / Dimensionally Incorrect / Incorrect Tooling / Unfit for Function / Setting Sheet
Gauge Inspection / 4 / 8 / 3 / 96
Incorrect Program / Unfit for Function / Setting Sheet
Gauge Inspection / 2 / 8 / 3 / 48
Incorrect Setting / Unfit for Function / Gauge Inspection / 4 / 8 / 3 / 96
Damage / Tooling / Unfit for Function / Visual Inspection / 3 / 7 / 4 / 84
Handling / Unfit for Function / Visual Inspection / 2 / 7 / 4 / 56
Contamination / Operator Error / Visually
Unacceptable / Visual Inspection / 3 / 7 / 4 / 84
Identification / Operator Error / Incorrect Parts
Supplied / Visual Inspection / 3 / 3 / 4 / 36
Tube / Furnace
Braise / Joint integrity / Blow holes / Unfit for Function / Visual Inspection / 4 / 4 / 2 / 32
Contamination / Unfit for Function / Visual Inspection / 3 / 4 / 2 / 24
Excess Braise / Unfit for Function / Visual Inspection / 4 / 4 / 2 / 32
Insufficient Braise / Parts May
Leak / Visual Inspection / 4 / 4 / 2 / 32
Missed Braise / Parts May
Leak / Visual Inspection / 4 / 4 / 2 / 32
Damage / Handling Damage / Unfit for Function / Visual Inspection / 3 / 4 / 4 / 48
Dimensionally Incorrect / Fit to checking fixture / Unfit for Function / Visual Inspection / 3 / 5 / 3 / 45
Identification / Supplier control / Incorrect Parts
Supplied / Visual Inspection / 3 / 3 / 4 / 36

FAILURE MODE & EFFECTS ANALYSIS – DESIGN / PROCESS

( CONTINUATION SHEET )

FMEA No

SHEET OF

ITEM / PART No
NAME
ISSUE / FUNCTION
OR
PROCESS / FAILURE
MODE / CAUSE OF
FAILURE / EFFECT OF FAILURE / CURRENT
CONTROLS / CURRENT STATUS / RECOMMENDED
CORRECTIVE
ACTION / ACTION
BY / ACTION
TAKEN / REVISED STATUS
OCC / SEV / DET / RPN / OCC / SEV / DET / RPN
Plating / Sub Con
Plating
Specification / Incorrect Specification / Sub contractor / Return to Supplier / Visual Inspection / 2 / 8 / 6 / 96
Damage / Sub contractor / Unfit for Function / Visual Inspection / 2 / 7 / 4 / 32
Identification / Sub contractor / Incorrect Parts
Supplied / Visual Inspection / 3 / 3 / 4 / 36
Assembly / Pressure Test / Leak / Poor Braising / Unfit for Function / Pressure Test Rig / 4 / 10 / 2 / 80
Damage / Handling / Unfit for Function / Visual Inspection / 2 / 7 / 4 / 56
Tooling / Unfit for Function / Visual Inspection / 2 / 7 / 4 / 56
Identification / Sub contractor / Incorrect Parts
Supplied / Visual Inspection / 3 / 3 / 4 / 36
Packing / Final Inspection / Incorrect To Fixture / Manufacturing Process / Unfit for Function / Gauge Inspection / 3 / 8 / 2 / 48
Contamination / Manufacturing Process / Contaminated
Parts Supplied / Blow Out
Visual Inspection / 3 / 5 / 4 / 60
Incorrect Labels / Operator Error / Incorrect Parts
Supplied / Operator Training
Visual Inspection / 3 / 3 / 4 / 60
Incorrect Packaging / Operator Error / Parts may be
Damaged / Operator Training
Visual Inspection / 3 / 4 / 4 / 48
Damage / Manufacturing Process / Damaged Parts Supplied / Operator Training
Visual Inspection / 3 / 7 / 4 / 48
Identification / Sub contractor / Incorrect Parts
Supplied / Visual
Inspection / 3 / 3 / 4 / 36

FAILURE MODE & EFFECTS ANALYSIS – DESIGN / PROCESS

( CONTINUATION SHEET )

FMEA No

SHEET OF

ITEM / PART No
NAME
ISSUE / FUNCTION
OR
PROCESS / FAILURE
MODE / CAUSE OF
FAILURE / EFFECT OF FAILURE / CURRENT
CONTROLS / CURRENT STATUS / RECOMMENDED
CORRECTIVE
ACTION / ACTION
BY / ACTION
TAKEN / REVISED STATUS
OCC / SEV / DET / RPN / OCC / SEV / DET / RPN
Tube / Hole / Dimensionally Incorrect / Incorrect Setting / Unfit for Function / Gauge Inspection / 3 / 8 / 3 / 72
Incorrect Tool Selection / Unfit for Function / Gauge Inspection / 3 / 8 / 3 / 72
Incorrect Orientation / Unfit for Function / Gauge Inspection / 3 / 8 / 3 / 72
Damage / Tooling / Unfit for Function / Visual Inspection / 3 / 7 / 4 / 84
Handling / Unfit for Function / Visual Inspection / 3 / 7 / 4 / 84
Deformation / Tooling / Unfit for Function / Visual Inspection / 3 / 7 / 4 / 84
Contamination / Excessive Swarf / Visually
Unacceptable / Visual Inspection / 3 / 7 / 4 / 48
Identification / Operator Error / Incorrect Parts
Supplied / Visual Inspection / 3 / 3 / 4 / 36
Tube / Trim / Excessive Trim / Operator Error / Detrimental to
End Form / Gauge Inspection / 4 / 8 / 3 / 96
Incorrect Setting / Detrimental to
End Form / Gauge Inspection / 4 / 8 / 3 / 96
Insufficient Trim / Operator Error / Detrimental to
End Form / Gauge Inspection / 4 / 5 / 3 / 60
Incorrect Setting / Detrimental to
End Condition / Gauge Inspection / 4 / 5 / 3 / 60
Identification / Sub contractor / Incorrect Parts
Supplied / Visual
Inspection / 3 / 3 / 4 / 36
Tube / Hand DeBurr / Excessive De burr / Operator Error / Detrimental to Weld / Visual Inspection / 3 / 7 / 4 / 84
Insufficient De burr / Operator Error / Detrimental To
End Form / Visual Inspection / 4 / 5 / 4 / 80
Identification / Operator Error / Incorrect Parts
Supplied / Visual Inspection / 3 / 3 / 4 / 36

FAILURE MODE & EFFECTS ANALYSIS – DESIGN / PROCESS

( CONTINUATION SHEET )

FMEA No

SHEET OF

ITEM / PART No
NAME
ISSUE / FUNCTION
OR
PROCESS / FAILURE
MODE / CAUSE OF
FAILURE / EFFECT OF FAILURE / CURRENT
CONTROLS / CURRENT STATUS / RECOMMENDED
CORRECTIVE
ACTION / ACTION
BY / ACTION
TAKEN / REVISED STATUS
OCC / SEV / DET / RPN / OCC / SEV / DET / RPN
Press / Dimensionally
Incorrect / Incorrect Setting / Unfit for function / Setting Sheet
Gauge Inspection / 3 / 5 / 4 / 60
Contamination / Surface Impregnation / Unfit for Function / Visual Inspection / 3 / 6 / 5 / 90
Damage / Tooling / Unfit for Function / Maintenance Sheet
Visual Inspection / 3 / 6 / 5 / 90
Operator Error / Unfit for Function / Operator Training
Visual Inspection / 3 / 6 / 5 / 90
Incorrect
Tool Selection / Unfit for Function / Setting Sheet
Visual Inspection / 3 / 6 / 5 / 90
Identification / Sub contractor / Incorrect Parts
Supplied / Visual
Inspection / 3 / 3 / 4 / 36
Burnish / Dimensionally Incorrect / Incorrect Setting / Unfit for Function / Setting Sheet
Gauge Inspection / 3 / 8 / 3 / 72
Incorrect
Tool Selection / Unfit for Function / Setting Sheet
Gauge Inspection / 3 / 8 / 3 / 72
Contamination / Surface Impregnation / Unfit for Function / Visual Inspection / 3 / 7 / 4 / 84
Handling / Unfit for Function / Operator Training
Visual Inspection / 3 / 7 / 4 / 84
Damage / Tooling / Unfit for Function / Maintenance Sheet
Visual Inspection / 3 / 7 / 4 / 84
Operator Error / Unfit for Function / Operator Training
Visual Inspection / 3 / 7 / 4 / 84
Identification / Operator Error / Incorrect Parts
Supplied / Visual
Inspection / 3 / 3 / 4 / 36
Tig Weld / Dimensionally
Incorrect / Incorrect Setting / Unfit for function / Gauge Inspection / 3 / 8 / 3 / 72
Contamination / Surface Impregnation / Unfit for Function / Visual Inspection / 3 / 7 / 4 / 84
Damage / Tooling / Unfit for Function / Maintenance Sheet
Visual Inspection / 3 / 7 / 4 / 84
Operator Error / Unfit for Function / Operator Training
Visual Inspection / 3 / 7 / 4 / 84
Incorrect
Tool Selection / Unfit for Function / Setting Sheet
Visual Inspection / 3 / 7 / 4 / 84
Incorrect No of Welds / Unfit for Function / Visual
Inspection / 3 / 4 / 4 / 48
Identification / Operator Error / Incorrect Parts
Supplied / Visual
Inspection / 3 / 3 / 4 / 36