EXAMPLE

System Potential FMEA Number

Subsystem Failure Mode and Effects Analysis Prepared By
Component (Design FMEA) FMEA Date
Design Lead Key Date Revision Date
Core Team Page of

Action Results
P

New RPN
New Occ
New Sev

New Det
S Potential Cause(s)/ D R Responsibility &
Potential Failure Potential Effect(s) r Current Design Recommended
Item / Function e Mechanism(s) of e P Target Completion Actions Taken
Mode(s) of Failure o Controls Action(s)
v Failure t N Date
b
Seals
Coolant
containment.
Hose
connection.
Coolant fill. M

Sensor mount. Compression set Leak 8 Gasket material 7 Pressure cycle 1 56 Use imported
Seal w/cold shock. material
Sensor mount. Loosen during Leak. Fall inside 8 Fitting not held 2 Added rib. 1 16 Implement J.P. Aguire
Seal sensor tank in place holding rib in 11/1/95
assembly/servic design. New
e fitting design.
Prototype
validation.

Sensor mount. Damaged Cannot install 5 Damaged during 2 1 10

Seal internal thread sensor installation or
transportation

Sensor mount. Damaged Cannot install 4 Damaged during 3 1 12 Damaged fitting

Seal external thread wire nut shipment to not used by
piracicaba Piracicaba

Coolant containment. Crack/break. Burst. Leak 8 Over pressure 8 Burst, validation 1 64 Test included in J.P. Aguire 11/1/95
Hose connection. Side wall flex. Bad pressure cycle. prototype and E. Eglin 8/1/96
Coolant fill. M seal. Poor hose rete production validation
testing.
Coolant containment. Crack/break. Burst. Failed mount 5 Vibration 9 Vibration w/road 3 135 Obtain GMB J.P. Aguire
Hose connection. Side wall flex. Bad tapes vibration road tape.
Coolant fill. M seal. Poor hose rete

Page 1
 EXAMPLE

System Potential FMEA Number

Subsystem Failure Mode and Effects Analysis Prepared By
Component (Design FMEA) FMEA Date
Design Lead Key Date Revision Date
Core Team Page of

Action Results
P

New RPN
New Occ
New Sev

New Det
S Potential Cause(s)/ D R Responsibility &
Potential Failure Potential Effect(s) r Current Design Recommended
Item / Function e Mechanism(s) of e P Target Completion Actions Taken
Mode(s) of Failure o Controls Action(s)
v Failure t N Date
b
Coolant containment. Crack/break. Burst. Hose leak 6 Overpressure. Poor 5 Burst, validation 2 60 Obtain GMB clamps J.P. Aguire 12/1/95
Hose connection. Side wall flex. Bad clamp pressure cycle and clamping
Coolant fill. M seal. Poor hose rete w/GMB clamps. specification.

Hold fluid, flow path, Stress crack Air conditioning does This is a test of the Operator instruction
Heat transfer not work. Sudden ADD POTENTIAL
structure refrigerant loss. CAUSE/MECHANIS
M OF FAILURE
system functionality
Hold fluid, flow path, Stress crack Air conditioning does This is a test of the This is a test of the
Heat transfer not work. Sudden ADD POTENTIAL ADD
structure refrigerant loss. CAUSE/MECHANIS RECOMMENDED
M OF FAILURE ACTION system
system functionality functionality
Hold fluid, flow path, Stress crack Leak. Loss of heat 8 Wicking. Material 7 Thermal cycle 1 56 Included in Product E. Eglin 8/1/96
Heat transfer transfer. strength Specification
structure
Hold fluid, flow path, Corrosion Air conditioning does this is a test while
Heat transfer not work. Sudden dan is here
structure refrigerant loss.

Hold fluid, flow path, Corrosion Leak. Loss of heat 8 Coolant quality. 7 SWAT, service 5 280 Brazilian coolant to J.P. Aguirre 11/1/95 Coolant ordered
Heat transfer transfer. Contamination. simulation. Coolant be evaluated. Zince
structure Environment - int/ext. evaluation. lined tubes may
need to be released.
Simulated service
test w/GMB coolant
to be performed.

Hold fluid, flow path, Puncture Leak. Loss of heat 8 External damage. 10 Leak test. Simulated 1 80 100% cores tested in E. Eglin 8/1/96
Heat transfer transfer. Coolant velocity. No service. production.
structure reinf sawcut. Simulated service
included in Product
Specificatin.
Hold fluid, flow path, Seam fail Leak. Loss of heat 5 Environment - int/ext. 1 SWAT, service 1 5 Included in Product E. Eglin 8/1/96
Heat transfer transfer. simulation. Specification.
structure
Hold fluid, flow path, Burst fail Leak. Loss of heat 8 Over pressure 2 Burst/leak pressure 5 80 GMB to study engine GMB 12/1/95 Study originated
Heat transfer transfer. contamination. cleanliness.
structure

Page 2
 EXAMPLE

System Potential FMEA Number

Subsystem Failure Mode and Effects Analysis Prepared By
Component (Design FMEA) FMEA Date
Design Lead Key Date Revision Date
Core Team Page of

Action Results
P

New RPN
New Occ
New Sev

New Det
S Potential Cause(s)/ D R Responsibility &
Potential Failure Potential Effect(s) r Current Design Recommended
Item / Function e Mechanism(s) of e P Target Completion Actions Taken
Mode(s) of Failure o Controls Action(s)
v Failure t N Date
b
Hold fluid, flow path, Plugged Loss of heat transfer. 8 Contamination. 7 1 56 GMB coolant to be J.P. Aguirre 11/1/95 Coolant ordered
Heat transfer Leakage due to Coolant quality. evaluated. GMB to
structure increase flow velocity study engine
cleanliness.
Hold fluid, flow path, Ballooning Leak. Loss of heat 5 Over pressure 9 8 360 GMB to study engine GMB 12/1/95
Heat transfer transfer. contamination. cleanliness.
structure Clustomer profile to
be determined.

Page 3