INSTRUCTION:

IN THE BLUE SECTIONS FOR AUTOMATIC INPUT INTO FORMS

Part Name PART NAME

Part Number PART NUMBER
Engineering Change Level REV NO.
Engineering Change Level Date ECN DATE

Organization Name COMPANY NAME

Organization Code SUPPLIER CODE OF COMPANY
Street Address ADDRESS
City CITY
State STATE
Country COUNTRY
Zip ZIP
Key Contact Number CONTACT PHONE NUMBER
Fax Number 555-555-5554
Customer Name DaimlerChrysler
Division DIVISION
Application VEHICLE MODEL

FMEA Number PART NUMBER

Email Address myself@mycompany.com
Process Flow Diagram
PART NUMBER: PART NUMBER DATE: 23-Jul-19
PART DESCRIPTION: ECL: REV NO.
PART NAME PREPARED BY:
PART / PROCESS

FABRICATION

ITEM #

ITEM #
INSPECT
INCOMING SOURCES OF DESIRED OUTCOME
STORE
MOVE

OPERATION DESCRIPTION PROCESS CHARACTERISTICS

NO.

VARIATION (PRODUCT CHARACTERISTICS)

Length 40 oversize 1 Total length 38 +/- 0.1

Length 40 Undersize 2 Step length 20 +/- 0.1
10 X CNC Machining -1 3 Step Outer Dia. 38.6 +/- 0.05 CNC Turning program.
Bore 10 Oversize
Bore 10 Undersize 4 Bore dia. 11.5 +/-0.1
Total length 38 +/- 0.1 less 1 Length 36 +/-0.1
Step length 20 +/- 0.1 less 2 Outer dia. 38.6 +/-0.05
Step Outer Dia. 38.6 +/- 0.05 3 Bore dia. 12 -0.000/+0.020
20 X CNC Machining -2 oversize or undersize CNC Turning program.
Bore dia. 11.5 +/-0.1 oversize or
undersize

30 X Broaching Bore dia. 12 -0.000/+0.020 1 Internal spline of bore (qualify to 1 Broching speed
undersize or oversize Go and Nogo spline gauge)

1 Coated with oil. 1 Grade of rust preventive oil.

40 X Oiling and storage in bin Not applicable
2 Stored in plastic bin. 2 Storage plastic bin type.
Potential Failure Mode And Effects Analysis (PFMEA)
Part Number PART NUMBER Engg. Change Level REV NO. FMEA Number: PART NUMBER
Part Name PART NAME Process Responsibil COMPANY NAME Prepared by: AB
Model Year(s)/Vehicle(s) VEHICLE MODEL Key Date 1-Jan-12 Date (Orig.) 31-Jul-19
Team: AB, PCN, KM, PKC. Date (Rev.)
C Potential O Current Current D
Part/ Process Potential Potential S l Cause(s)/ c Process Process e R. Recommended Responsibility Action Results
Process Function/ Failure Effect(s) of e a Mechanism(s) c Controls Controls t P. Actions & Target Actions S O D R.
Number Require- Mode Failure v s of Failure u Prevention Detection e N. Date Taken e c e P.
ments s r c v c t N.
CNC Machining -1: Outer dia. Oversize A Portion of Production run may 5 Incorrect Tool offset 3 Trained CNC Sampling inspection by 6 90 None NA NA
Outer Dia. Machined have to be reworked offline and operator vernier calipers after tool
38.6 +/- 0.05 accepted. offset (post processing
inspection).

10 Outer dia. Undersize A portion of the production run may 7 Incorrect Tool offset 3 Trained CNC Sampling inspection by 6 126 None NA NA
have to be scrapped. operator vernier calipers after tool
offset (post processing
inspection).

CNC Machining -1: Bore dia. Oversize A portion of the production run may 7 Incorrect Tool offset 3 Trained CNC Sampling inspection by air 6 126 None NA NA
Bore Dia. Machined have to be scrapped. operator bore gauge after tool offset
11.5 +/- 0.1

10 Bore dia. Undersize A Portion of Production run may 5 Incorrect Tool offset 3 Trained CNC Sampling inspection by air 6 90 None NA NA
have to be reworked offline and operator bore gauge after tool offset
accepted. (post processing inspection).

CNC Machining -1: Machined length No effect 1

Machined length Overdersize
20 +/-1

10 Machined length A portion of the production run may 7 Incorrect Tool offset 3 Trained CNC Sampling inspection by 6 126 None NA NA
Undersize have to be scrapped. operator and vernier calipers after tool
validated CNC offset (post processing
Program. inspection).

CNC Machining -1: Total length Oversize No effect 1

Total length
38 +/-1

10 Total length A portion of the production run may 7 Incorrect Tool offset 3 Trained CNC Sampling inspection by 6 126 None NA NA
Undersize have to be scrapped. operator vernier calipers after tool
offset (post processing
inspection).

Length oversize A Portion of Production run may 5 Incorrect Work offset 3 Trained CNC Sampling inspection by 6 90 None NA NA
have to be reworked offline and operator and vernier calipers after tool
accepted. validated CNC offset (post processing
Program. inspection).
CNC Machining -2:
20 Length 36 +/-0.1 Length Undersize A portion of the production run may 7 Incorrect Work offset 3 Trained CNC Sampling inspection by 6 126 None NA NA
have to be scrapped. operator and vernier calipers after tool
validated CNC offset (post processing
Program. inspection).

Outer dia Oversize A Portion of Production run may 5 Incorrect Tool offset 3 Trained CNC Sampling inspection by 6 90 None NA NA
have to be reworked offline and operator and vernier calipers after tool
accepted. validated CNC offset (post processing
Program. inspection).
CNC Machining -2:
20 Outer dia. 38.6 +/-
Outer dia Undersize A portion of the production run may 7 Incorrect Tool offset 3 Trained CNC Sampling inspection by 6 126 None NA NA
0.05
have to be scrapped. operator and vernier calipers after tool
validated CNC offset (post processing
Program. inspection).

Bore dia Oversize Can increase the Lead Error in Gear 7 Incorrect Tool offset 4 Trained CNC Sampling inspection by air 6 168 100% Inspection by 100% Inspection by 7 4 5 140
causing deteroration of function of operator and bore gauge after tool offset air bore gauge air bore gauge
gear. Degradation of primary validated CNC (post processing inspection). (equivalent to in- implemented on 01-
function (vehicle operable, but at Program. line inspection). Aug-19.
reduced level of performance). 1-Aug-19
CNC Machining -2:
20 Bore dia. 12 -
0.000/+0.020
Potential Failure Mode And Effects Analysis (PFMEA)
Part Number PART NUMBER Engg. Change Level REV NO. FMEA Number: PART NUMBER
Part Name PART NAME Process Responsibil COMPANY NAME Prepared by: AB
Model Year(s)/Vehicle(s) VEHICLE MODEL Key Date 1-Jan-12 Date (Orig.) 31-Jul-19
Team: AB, PCN, KM, PKC. Date (Rev.)
C Potential O Current Current D
Part/ Process Potential Potential S l Cause(s)/ c Process Process e R. Recommended Responsibility Action Results
Process Function/ Failure Effect(s) of e a Mechanism(s) c Controls Controls t P. Actions & Target Actions S O D R.
Number CNC Machining
Require- -2: Mode Failure v s of Failure u Prevention Detection e N. Date Taken e c e P.
20 Bore dia. 12 -
ments
0.000/+0.020 s r c v c t N.
Bore dia Undersize Problem in putting the part in gear 7 Incorrect Tool offset 4 Trained CNC Sampling inspection by air 6 168 100% Inspection by 100% Inspection by 7 4 5 140
cutting fixture. A portion of the operator and bore gauge after tool offset air bore gauge air bore gauge
production run may have to be validated CNC (post processing inspection). (equivalent to in- 1-Aug-19 implemented on 01-
scrapped. Program. line inspection). Aug-19.
Potential Failure Mode And Effects Analysis (PFMEA)
Part Number PART NUMBER Engg. Change Level REV NO. FMEA Number: PART NUMBER
Part Name PART NAME Process Responsibil COMPANY NAME Prepared by: AB
Model Year(s)/Vehicle(s) VEHICLE MODEL Key Date 1-Jan-12 Date (Orig.) 31-Jul-19
Team: AB, PCN, KM, PKC. Date (Rev.)
C Potential O Current Current D
Part/ Process Potential Potential S l Cause(s)/ c Process Process e R. Recommended Responsibility Action Results
Process Function/ Failure Effect(s) of e a Mechanism(s) c Controls Controls t P. Actions & Target Actions S O D R.
Number Require- Mode Failure v s of Failure u Prevention Detection e N. Date Taken e c e P.
ments s r c v c t N.
Spline GO gauge not Can cause fiment problem in 7 Broach dimension 3 Dimensional Sampling inspection by Spline 7 147 100% Inspection by 7 3 6 126
qualifty (underize) assembly line of gear box. A portion Undersize inspection of new Go gauge (post processing Spline Go gauge 100% Inspection by
of the production run may have to and re-sharpened inspection). (equivalent to in- Spline Go gauge
be scrapped. broach. line inspection). 1-Aug-19
implemented on 01-
Aug-19.
Broaching:
30 Spline to qualify Spline No GO gauge Can cause noise in gear box in 7 Broach dimension 3 Dimensional Sampling inspection by Spline 7 147 100% Inspection by 7 3 6 126
Gauge qualifty (Overize oc vehicle operation. Degradation of Oversize inspection of new No Go gauge (post processing Spline No Go gauge
spline PCD) primary function (vehicle operable, and re-sharpened inspection). (equivalent to in- 100% Inspection by
but at reduced level of broach. line inspection). Spline No Go gauge
performance). 1-Aug-19
implemented on 01-
Aug-19.

Oil coating is not Rust formation in parts before gear 7 Part not dipped 3 Trained operator 100 % Visual check by 8 168
made on some cutting operation. A portion of the completely in oil. and RP Oil is made operator.
portion of surface. production run may have to be easily available in
scrapped. shop.

Excessive oil coatong Problem in putting the part in gear 7 Oil is very thick. 2 FIFO of RP Oil is 100 % Visual check by 8 112
on part . cutting fixture. A portion of the made in store so operator.
production run may have to be that old oil is not
scrapped. issued to work
shop.
Oiling and storage in
40 bin.
Dent in part. Can cause noise in gear box in 7 Hitting of part with 2 Designated bin Error (Cause) prevention as a 1 14
vehicle operation. Degradation of metallic bin. with guide rod result of fixture design.
primary function (vehicle operable, provided for Discrepant parts cannot be
but at reduced level of storage which has made because item has been
performance). PVC coating for error-proofed by process
dent prevention in design.
part during
handling.
Control Plan
Engineering Change Documents are
Prototype Pre-Launch Production
attached
Control Plan Number Key Contact/Phone CONTACT PHONE NUMBER Date (Orig.) Date (Rev.)
PART NUMBER
Part Number Engg. Change Level Core Team AB, PCN, KM, PKC. Customer Engineering Approval/Date (If Req'd.)
PART NUMBER REV NO.
Part Name/Description Supplier/Plant Approval/Date 31-Jul-19 Customer Quality Approval/Date (If Req'd.)
PART NAME
Supplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)
MACHINE, CHARACTERISTICS METHODS REACTION
PART/ PROCESS NAME/ DEVICE, NO. PRODUCT PROCESS SPL PRODUCT/PROCESS EVALUATION/ SAMPLE CONTROL PLAN
PROCESS OPERATION JIG,TOOLS, CHAR. SPECIFICATION/ MEASUREMENT SIZE FREQ. METHOD
NUMBER DESCRIPTION FOR MFG. CLASS TOLERANCE TECHNIQUE
10 CNC Machining - 1 CNC Turning Machine 1 Outer dia. 38.6 +/- 0.05 Digital VC 1 Setting and Recording in In- - Tool offset
with Turning tool and every hour process inspection - Insert change
insert for facing and 2 Total length 38.0 +/- 0.1 Digital VC report.
Outer dia turning. 3 Step length 20.0 +/- 0.1 Digital VC
4 Bore dia. 11.5 +/- 0.1 Air Bore Gauge
1 CNC Program CNC Program no. xxxx. Use the specified CNC
Program, which is locked for
change.

20 CNC Machining - 2 1 Outer dia. 38.6 +/- 0.05 Digital VC 1 Setting and Recording in In- - Tool offset
every hour process inspection - Insert change
2 Total length 36.0 +/- 0.1 Digital VC report.
3 Bore dia. 12.0 + 0.020 / - 0.000 Air Bore Gauge 3 100%
Inspection
1 CNC Program CNC Program no. yyyy. Use the specified CNC
Program, which is locked for
change.

30 Broaching Vertical Broaching 1 Spline of Bore Spline Go Gauge to qualify and Spline Go and No Go Gauge 1 100% Recording in In- Change Broach
Machine No Go Gauge not to pass. Inspection process inspection
report.

1 Broaching Speed Speed Setting Knob Position - 2.

40 Oiling and storage in Plastic Bin of Rust 1 Oil coating on Oil coating all over the part Visual Check 100% NA Recording in In- Add oil to oil bin.
bin Preventive oil (DW part process inspection
Grade), report.
Plastic storage bin
with PVC coated
vertical rods.
1 Complete dipping
in bin of RP Oil.