PotentialFailureModeAndEffectsAnalysis(FMEA)(1)

PropertyofFordMotorCompanyInternalUseOnlyThecontentofthisdocumentisthetechnicalequivalentofSAEJ-1739.PotentialFailureModeandEffectsAnalysis(FMEA)shouldbeusedbysupplierstocompaniessubscribingtoQS-9000orequivalentdocument.POTENTIALFAILUREMODEANDEFFECTSANALYSIS(FMEA)REFERENCEMANUALFirstEditionIssuedFebruary,1993•SecondEdition,February,1995•ThirdEdition,July,2001Copyright©1993,©1995,©2001DaimlerChryslerCorporation,FordMotorCompany,GeneralMotorsCorporationPropertyofFordMotorCompanyInternalUseOnlyFOREWORD1stand2ndEditionThisreferenceManualandReportingFormatwasdevelopedbytheFailureModeandEffectsAnalysis(FMEA)teamsatChrysler,FordandGeneralMotors,workingundertheauspicesoftheAutomotiveDivisionoftheAmericanSocietyforQualityControl(ASQC)andtheAutomotiveIndustryActionGroup(AIAG).TheASQC/AIAGTaskForcecharteristostandardizethereferencemanuals,procedures,reportingformatsandtechnicalnomenclatureusedbyChrysler,Ford,andGeneralMotorsintheirrespectivesupplierqualitysystems.Accordingly,thismanualandformat,whichisapprovedandendorsedbyChrysler,FordandGeneralMotors,shouldbeusedbysuppliersimplementingFMEAtechniquesintotheirdesign/manufacturingprocesses.Inthepast,Chrysler,FordandGeneralMotorseachhadtheirownguidelinesandformatsforinsuringsupplierFMEAcompliance.Differencesbetweentheseguidelinesandformatsresultedinadditionaldemandsonsupplierresources.Toimproveuponthissituation,Chrysler,FordandGeneralMotorsagreedtodevelop,and,throughAIAG,distributethisManual.TheworkgroupresponsiblefortheManualwasledbeGeorgeBaumgartnerofFordMotorCompany.ThisManualprovidesgeneralguidelinesforpreparinganFMEA.ItdoesnotgivespecificinstructionsonhowtoarriveateachFMEAentry,ataskbestlefttoeachFMEAteam.ThisManualalsoisnotintendedtobeacomprehensiveFMEAreferencesourceortrainingdocument.Whiletheseguidelinesareintendedtocoverallsituationnormallyoccurringeitherinthedesignphaseorprocessanalysis,therewillbequestionsthatarise.Thesequestionsshouldbedirectedtoyourcustomer'sSupplierQualityAssurance(SQA)activity.IfyouareuncertainastohowtocontacttheappropriateSQAactivity,thebuyerinyourcustomer'sPurchasingofficecanhelp.TheTaskForcegratefullyacknowledges:theleadershipandcommitmentofVicePresidentsThomasT.StallkampatChrysler,NormanF.EhlersatFord,andJ.IgnasioLopezdeArriortuaofGeneralMotors;theassistanceoftheAIAGinthedevelopment,production,anddistributionoftheProcedure;theguidanceofTaskForceprincipalsRussJacobs(Chrysler),SteveWalsh(Ford),DanReid(GeneralMotors),andRadSmith;andtheassistanceoftheASQCAutomotiveDivisionReadingTeam.Thisteam,ledbyTrippMartin(PetersonSpring),reviewedtheManualfortechnicalcontentandaccuracyandmadevaluablecontributionstoformandcontent.SincetheManualwasdevelopedtomeetspecificneedsoftheautomotiveindustry,theASQCvoluntarystandardsprocessdefinedbyASQCpoliciesandprocedureswasnotusedinitsdevelopment.AdditionalcopiescanbeorderedfromAIAGand/orpermissiontocopyportionsofthisProcedureforusewithinsupplierorganizationsshouldbeobtainedfromAIAGat248-358-3003.PropertyofFordMotorCompanyInternalUseOnlyPropertyofFordMotorCompanyInternalUseOnlyPropertyofFordMotorCompanyInternalUseOnlyFOREWORD3rdEditionTheFMEA3rdEdition(QS-9000)isareferencemanualtobeusedbysupplierstoDaimlerChrysler,FordMotorCompany,andGeneralMotorsCorporationasaguidetoassisttheminthedevelopmentofbothDesignandProcessFMEAs.Thisreferencemanualisintendedtoclarifyquestionsconcerningthetechni-caldevelopmentofFMEAs.ThisreferencemanualisconsistentwiththeSupplierQualityRequirementsTaskForcechartertostandard-izethereferencemanuals,procedures,reportingformatsandtechnicalnomenclatureusedbysupplierstoDaimlerChrysler,FordMotorCompany,andGeneralMotorsCorporation.AccordinglytheFMEA,3rdEditionManualiswrittentoprovideguidanceforthesupplier.Themanualdoesnotdefinerequirements,itdoesprovidegeneralguidelinesintendedtocoversituationsnormallyoccurringwhenpreparingFMEAsduringthedesignphaseorprocessanalysisphase.ThismanualisthetechnicalequivalentofSAEJ1739,forDesignandProcessFMEAs.However,itdoesnotincludeanapplicationforMachineryFMEA.InterestedpartiesinMachineryFMEAmayrefertoSAEJ1739forarelatedexample.TheSupplierQualityRequirementsTaskForcewouldliketothankthefollowingindividuals,andtheircompanies,whohavecontributedtheirtimeandeffortstothedevelopmentofeitherthiseditionoftheFMEAmanualorearliereditions.3rdEditionKevinA.Lange-DaimlerChryslerStevenC.Leggett-GeneralMotorsCorporationBethBaker-AIAGEarlierEditionsHowardRiley-DaimlerChryslerMarkT.Wrobbel-DaimlerChryslerGeorgeR.Baumgartner-FordMotorCompanyRebeccaFrench-GeneralMotorsLawrenceR.McCullen-GeneralMotorsMaryAnnRaymond-BoschRobertA.May-GoodyearWilliamIreland-Kelsey-HayesTrippMartin-PetersonSpringInaddition,theSupplierQualityRequirementsTaskForcewouldliketothankthefollowingindividualsfromtheSAEJ1739workgroupwhocontributedsignificantlytothetechnicalchangesandimprovementsinthisedition.WilliamD.Carlson-DaimlerChryslerGlenR.Vallance-FordMotorCompanyCarlS.Carlson-GeneralMotorsCorporationThismanualisacopyrightofDaimlerChrysler,FordMotorCompanyandGeneralMotorsCorporation,withallrightsreserved.Addit