WHFM/01/01
PROCESS FAILURE MODE AND EFFECT ANALYSIS (P-FMEA)
MODEL NAME: Landi Ranzo
MODEL NO.: 273 & 274
Process Process Function
Potential Failure Mode
No. Requirements
Wires donot match the required
specs
1 RECEIVING
Sheet Metal Parts out of Spec
Rubber & Plastic Parts Out of
Spec
Cut wire not the One on the
drawing (Wrong Wire)
CUTTING/
2 machine
STRIPPING
Wire Length Short or Longer than Assembly Not Possible
the Spec limits
Extra Wires result in wrong assembly
Crimping Not Possible
Wrong Stripping
Unacceptable for next operation
Wrong terminal crimp, not
according to Job Card
Insulation Barrel Broken
3 Crimping
Damaged wires, Bite on Wires
Strands not visible from the point Chances of Wires coming loose from
of insulation.
Strands not visible post crimping
point
Terminals Get Oxidized
Wrong Insertion
4 SUB ASSEMBLY Wire Miss
Terminal not locked properly
Wire/ Insulation damaged
Rev.Date : 24/02/08
FMEA Key Date: 10-Dec-08
PROCESS RESPONSIBILITY: Thal Engineering Limited MODEL YEAR / VEHICLE: 2008
CUSTOMER AFFECTED: Landi Ranzo CORE TEAM: Sajida Mateen, Adeel Siddiqui
FMEA Date: 18-Sep-08 FMEA Revision Date: - Rev. # NA
Action Remarks
Occurrence
Detection
Severity
Occurrenc
Detection
Severity
Responsibility &
Class
Potential Cause(s) / Recommended Target
RPN
Potential Effect(s) of Failure Current Process Controls Action
RPN
Completion
Mechanism(s) Actions
e
Date Taken
In Coming Material received on Wrong In Coming Inspection as per Control
Unacceptable for next operation
tag Plan
3 2 3 18
In Coming Inspection as per Control
Line Delay Wrong Shipment from Supplier
Plan
Unacceptable for next operation In Coming Inspection.
3 Wrong Parts Shipped by Supplier 2 3 18
Line Delay SOP at all Production Process, FO
Unacceptable for next operation Wrong Parts Shipped by Supplier In Coming Inspection.
3 2 3 18
Line Delay Parts Got defromed/ damaged SOP at all Production Process, FO
Sub Assembly Not Possible Wrong wire specs on the Job card
Time loss Job card not readable FO Procedure, QA Inspection, Operator
4 3 3 36
Inspection
Wrong Job Card Distributed at the
Material Wastage
Wrong Job Cards Used FO Procedure, QA Inspection as Per
4 2 3 24
Control Plan
Job Card Not followed
Wrong data fed in machine FO Procedure, QA Inspection
4 2 3 24
Job Card Not Followed FO Procedure, QA Inspection
Job Cards, Set Up procedure, FO
Terminal will not lock properly Wrong Specs
Procedure, Sub Assembly SOP
Job Cards, Set Up procedure, FO
Can not perform the intended function 5 Wrong Terminal reel on the machine 2 3 30
Procedure, Sub Assembly SOP
Wrong Job Card attached with the Job Cards, Set Up procedure, FO
termianl reverse
bunch of cut wires Procedure, Sub Assembly SOP
Crimping Specs based on Pull Test Spec Cards based on Pull Test, Setup
Cannot perform the intended function 6 3 4 72 Japanese Crimping QA & R&D Team Japanese 6 1 4 24
doesn’t guarantee proper crimping inspection, QA FO Inspections.
Specs to be Crimping
Implemented instead Specs from
Chances of Wires coming loose from Crimping Specs based on Pull Spec Cards as per Japanese Specs, of Pull Test based FAS
6 3 4 72 Crimping Specs. 31-Mar-08 implemented 6 1 4 24
Terminal Testdoesn’t guarantee proper crimping Setup inspection, QA FO Inspections.
Crimping Specs doesn’t guarantee Spec Cards as per Japanese Specs,
5 2 3 30
Terminal proper crimping Setup inspection, QA FO Inspections.
Chances of Wires coming loose from Crimping Specs doesn’t guarantee Spec Cards as per Japanese Specs,
5 2 3 30
Terminal proper crimping Setup inspection, QA FO Inspections.
Terminals covered with special bags
Cannot perform the intended function 4 Terminals are exposed to air 2 3 24
when not in use.
Sub Assembly Inspection, FO, ECT
Cross circuit In correct Drawing
Process
4 2 3 24
Sub Assembly Inspection, FO, ECT
Short Circuit Connector Direction. Not followed
Process
Assembly instructions, drawing not Sub Assembly Inspection, ECT
Cannot perform the intended function 4
followed.
2
Process.
2 16
Terminal reverse 5 Insert-Click-Pull not followed 2 Insert, Click and Pull SOP, ECT 3 30
Unacceptable for next operation 4 Mis Handling. 3 Operator's Instructions, FO, FVI. 3 36
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 Sub Assembly Inspection, FO, ECT
Cross circuit In correct Drawing
Process
Wrong Insertion 4 2 2 16
Sub Assembly Inspection, FO, ECT
Short circuit Connector Direction. Not followed
Process
Jigs, Visual Aids, Final Visual
Not usable at customer end No error proofing at the station
Inspection.
Component Missing 4 4 3 48
Jigs, Visual Aids, Final Visual
Product failure at ECT Material short supply on line
Inspection.
FINAL Dirt on Connectors Cannot confirm to the Quality Standards 3 Marks of Fabric Tape 4 Rework cards on reowrk harness 2 24
5
ASSEMBLY
Visual
Visual Controls on All Production & QA (6
Wrong Tape Used Cannot confirm to the Quality Standards 5 Tape Types not Clear to Operator 4 Shopping List and visual inspections 4 80 Controls 5 1 3 15
Boards Needed Dec. 2007)
Installed
Proper Tools not used for cutting the
Tie Clip Band Not cut as oer spec Not Acceptable for next Process 3 4 Tyton Guns with proper torques. 3 36
bands
Product Handling SOP, FO, QA
Wire/ Insulation damaged Unacceptable for next operation 4 Damaged due to mis handling. 3 4 48
Inspections, FVI
Wire lenghts not as per drawing/
Unable to Assemble. 4 Job Card not followed. 4 SOP, QA Inspection, FVI 3 48
drawing board

Harness delivered to the next sec. Product Quality/ functionality is not ECT Pass Tape Check on next
4 Name Sheet missing. 2 5 40
Without ECT assured operation 100%

Pass harness moved without

Second time ECT to be performed 3 Stamp not available at the station 2 Stamp Check on next operation 100% 5 30
ELECTRIC stamp
6 CONTINUITY
TEST (ECT) Harness move to the next section
Harness may be sent to the OEM. 5 Harnesses almost identical 2 Stamp Check on next operation 100% 4 40
with wrong name sheet.

Product Quality/ functionality is not ECT unable to detect the wrong Computer software doent issue a pass
ECT passed a wrong insertion 6 2 2 24
assured insertion. sheet

Cant not detect Exterior parts Visual Aids, Jigs, Master Sample,
Harness not usable by customer 6 Master sample, SOP Not Followed 1 5 30
missing. Training

Visual Aids, Jigs, Master Sample,

Cant detect Branch length short Harness will not fit properly into vehicle 6 Master sample, SOP Not Followed 1 5 30
Training
FINAL VISUAL
7
INSPECTION (FVI)
Visual Aids, Jigs, Master Sample,
Cant Detect Wrong fuse insertion. Fuse or devices not working into vehicle 6 Master sample, SOP Not Followed 1 5 30
Training

Cant Detect Wrong exterior part Harness will not fitted properly into Visual Aids, Jigs, Master Sample,
6 Master sample, SOP Not Followed 1 5 30
mounting. vehicle Training

Visual Aids, igs, Process & Product

Cant Catch a wire/ PVC damage Short circuit mal Functioning of system 6 Safe Handling procedures not followed 1 5 30
Audits, Pre-Ship Audits.

PRE DELIVERY
8 INSPECTION Unable to Catch a Wrong name Visual Aids, igs, Process & Product
(PDI) Harness can mount wrong vehicle 6 Check & Mark not done 1 5 30
sheet Audits, Pre-Ship Audits.

Unable to determine a Wrong/ Harness will not fitted properly into Critical parts are not visually checked & Visual Aids, igs, Process & Product
6 1 5 30
Damaged/ Missing Par vehicle marked. Audits, Pre-Ship Audits.

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Parts Damaged during Shipment
Un-Safe Packing
Parts get damaged at customer ware
house during handling.
9 PACKAGING
Wonrg Part Packing Delay on customers' Line
Pre-Ship Audits
5 Insufficient training 2 5 50
SOP, Training and training Audits
Proper training of Operators
5 Proper Packing Material Not Used 2 5 50
Pre-Ship Audits
Pre-Ship Audits
5 Insufficient training 2 5 50
Training Audits

Pre-Ship Audits
Wrong Quantity sent to customer Delay on customers' Line 5 Insufficient training 2 5 50
Training Audits

Periodic Product Audit at Dispatch

Delayed part to line Insufficient training
VisuaL aids
Wrong labeling 6 2 4 48
Periodic Product Audit at Dispatch
10 DISPATCH Wrong part to line Label Printer malfunction
Lay out Audit

SOP & Training

Incorrect Order quantity on the dispatch
Incorrect Quantity of Boxes Delay on Line 5 1 4 20
sheet
Dispatch Checklist.

** Significant
Characteristics

Prepared By: Checked By: Approved By:

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