221859366 f169 Dfmea Front Strip System 01feb2001

8/12/2019 221859366 f169 Dfmea Front Strip System 01feb2001

1/29

Design Failure Mode and Effects Analysis (DFMEA) Instructions

NOTE: Design FMEAs must be prepared for all programs (components, subassemblies and assemblies)

where Johnson Controls has full program design responsibility. In cases where the OEM Customer has

design responsibility, every effort must be made to document special and safety critical special

characteristics for inclusion in the Design FMEA and Control Plan. (A matrix for this purpose and the

FMEA Form can be found in the AIAG APQP and Control Plan manual).

INSTRUCTIONS:

1. The System FMEA and/or Design FMEA are to be prepared using the DaimlerChrysler, Ford, and General

Motors Potential Failure Mode and Effects Analysis (FMEA) reference manual.

2. Historical campaign, warranty data, high mileage data and P-Diagram noise factors must be reviewed and

included in the DFMEA as applicable.

3. Similar part/program DFMEA's must be considered when preparing a DFMEA for all new programs.

4. The SFMEA and/or DFMEA must identify and address all Special Characteristics (both significant andcritical).

5. Design characteristics that affect high risk priority failure modes must be identified.

6. Appropriate corrective actions must be assigned to high risk priority numbers (RPN 70 and greater).

7. Appropriate corrective actions must be planned and/or taken for high severity numbers (severity of 7 and

greater).

8. Risk priorities must be revised when corrective actions have been completed and verified.

9. Customer system design specifications numbers must be indicated for each failure mode. (i.e. Ford SDS

v4.0, ST-0018 and GM SOR-SSTS xxx)

10. DFMEAs must address all failure modes in areas of Safety, Function, Service, Appearance, BSR,

Assembly, Packaging and Comfort.

WW-PLUS-FR-04-31-E / Rev 01 Page 1 of 29


2/29

POTENTIAL

FAILURE MODE AND EFFECTS ANALYSIS

(DESIGN FMEA)

Customer Design Spec. TJC F169 02 Rev : B

Item: FIAT169 - FRONT SEAT - STRIP VER COMPLETE SYSTEM Design Responsibility:

Customer/Model Year/Platform/Product: FIAT/ 2002/ / STRIP VERSION

Team: MG / TKK / VD / SP / MP / SAI / AG / RAO

C Potential O D

te Item Potential Potential S l Cause(s)/ c Current e R. Recomm

# Function/ Failure Effect(s) of e a Mechanism(s) c Design t P. Actio

Require- Mode Failure v s of Failure u Controls e N.

ments s r c

Assy Front seat

238442, 238443

1 Safety/ Seat

System to

provide flush

fitting

components/min. clearance to

components

with relative

motion

Seat System does not

provide flush fitting

components/min.

clearance to

components withrelative motion

Occupants finger

becomes trapped.

5 SC Incorrect gap size

specified on

valance/recliner covers

3 Seat side

valance/recliner cover

to cushion gap to be

less than 5 mm or

greater than 20 mm.

2 30

5 Incorrect gap size

specified on flip up

cushion system

3 Flip up cushion

mechanism to

occupant handle

location to be less than

5 mm or greater than

20 mm.

2 30

5 4 way lifter handle grip

area to side valance

gap size incorrectly

specified

3 During arc of

movement lever grip

area not to be within 30

mm of sidevalance/door bin

3 45

5 Recliner handwheel

grip area to recliner

cover gap size

incorrectly specified

2 Recliner handwheel to

recliner cover to be

less than 5 mm or

greater than 20 mm.

2 20

Occupants

belongings fall into

seat system

5 Incorrect gap sizes

specified within seat

system

3 Layout study. Prototype

evaluation

2 30

WW-PLUS-FR-04-31-E / Rev 01


3/29

POTENTIAL


(DESIGN FMEA)





C Potential O D




ments s r c

5 Ornamentation permits

objects to be funnelled

into seat system

3 Top edge of valance to

flow under seat

cushion.

4 way lifter handle to

side valance to

interlock. Max gap

between adjacent

components 2 mmRear of cushion to

recliner cover/valance

2 30

Occupant clothing

catches/snags

5 Release handle system

protrudes into

ingress/egress zone

3 Towel bar sytem with

continuous bar from I/b

to o/b slide system

2 30

5 4 way lifter handle

protrudes into

ingress/egress zone

4 Prototype evaluation 4 80 Fiat styling an

groups to agr

and location.

Limited access to

belt buckle. Foul

condition to

adjacent

components.

5 Belt buckle clearance

to console.

3 Layout study. Prototype

evaluation

3 45

5 Pretensioner tube andbracket clearance to

console.

2 Layout study. Prototypeevaluation

3 30

2 Safety/Seat

system not to

affect other

systems/compo

nents/occupant

with sharp

edges

Seat system does

affect other

systems/components/o

ccupant with sharp

edges

Occupant injury. 9 CC Incorrect design. 1 Min bend radii 5 mm.

No forward facing

structure free edges.

Cover Track edges in

occupant reach by safe

edge/de-burred

Safe edge around front

of pan, covered by

trim/plastic.

ECE R 17.

1 9 Make min rad

than min lega

amount than

tolerance ban

factor



4/29

POTENTIAL


(DESIGN FMEA)





C Potential O D




ments s r c

9 SC Towel bar track release

sytem grip area

1 Dia 10 mm min tube.

Layout study and

prototype evaluation

1 9

9 SC 4 way lif ter lever grip

area

2 Radi i Min 2 mm.

Smooth profile

Plastic grip area with

no tool parting lines in

grip area

2 36

9 SC Recliner handwheel

grip area

2 Santoprene outer grip

area

Plastic housing - Min

rad 0.5 mm.

2 36

9 SC Valance/recliner cover

edge

2 Full rad around

perimeter (Styling

approval required from

Fiat)

No tooling split lines on

A surface or self

2 36

Seat belt damage. 9 YC Incorrect desiign of

upper cross member

may make sharp edges

possible.

1 Protection cap fitted to

all front seat back

frames.

This fixture was POKE

YOKE in all JIT plants.

1 9

9 YC Forward facing edges 1 Layout study. Prototype

evaluation

1 9

3 Safety/Seat

system to

provide a fire

resistant

system.

Seat system does not

provide a fire resistant

system.

Occupant injury. 9 YC Incorrect material

specification.

2 Material specifications.

FMVSS 302.

2 36



5/29

POTENTIAL


(DESIGN FMEA)





C Potential O D




ments s r c

4 Safety/Seat

system to

provide an

electrically safe

system


provide an electrically

safe system

Occupant injury. 9 YC Incorrect specification

ofelectrical

components.

2 Legal legislation.

Electrical system

specification.

Controlled by supplier

TRW according to Fiat

specifications.

2 36

9 YC Incorrect cable routing 1 Route cables to protect

from side impact. Fiatapproval required.

3 27

9 YC Water ingress into

connector system

2 Locate away from

water ingress zone.

If in zones use sealed

type connector

2 36

Electrical system

failiure.

6 Loss of electrical signal 3 Connector to connector

latching strength - 100

N min.

Free cable length for

height adjust and flip

up cushion systems.

Mount connectors on

2 36

5 Safety/Seat

system toprovide an

ocupant with a

protected

environment.

System does not

provide a protectedenvironment for the

occupant.

Occupant injury. 9 YC Headrestraint becomes

detached from seatstructure

3 Notch depth 2.0 mm

Button diameter 0.8mm ECE R

25.04

ECE R 17.07

2 54

9 YC Incorrect Packaging. 2 Layout study, Prototype

evaluation, Customer

sign off.

2 36

10 YC Incorrect material

selection

2 Material specifications

based on FEA,

Surrogate parts

2 40



6/29

POTENTIAL


(DESIGN FMEA)





C Potential O D




ments s r c

6 Safety/Seat

system to

provide correct

package

clearances.

System does not

provide correct layout

clearances.

Customer

dissatisfaction.

7 YS Seat movemnts

incomplete due to

interference within

structure

2 Kinematic studies in

CAD, Functional seat

build

3 42

7 YS Seat movemnts

incomplete due tointerference with other

systems

3 Kinematic studies in

CAD, Prototypeevaluation in vehicle

2 42

7 Safety/Seat

system to

provide

adequate

strength under

static and/or

dynamic

loadings


provide adequate

strength under static

and/or dynamic

loadings

Occupant injury. 10 YC New seat structure

design/Incorrect

design.

2 ECE R 14.05,ECE R

16.04,ECE 17.07,ECE

R 21.01,ECE R

25.04,ECE R

94.01,ECE R 95.01

Engineering issues list.

Customer sign off.

Homologation.

Surrogate structure

3 60

10 YC Flipup cushion self

activates

2 Front X tube interlock

load path with pan

ECE 17

ECE 14, Surrogate

mechanism

2 40

8 Safety/Seat

user adjust

components to

provide

adequate

strength under

static and/or

dynamic

loadings

Seat user adjust

components do not

provide adequate

strength under static

and/or dynamic

loadings

Loss of

adjustment/feature

function

8 YS Incorrect specification

on material section

2 FEA

Free body diagrams

Surrogate mechanisms

2 32



7/29

POTENTIAL


(DESIGN FMEA)





C Potential O D




ments s r c

8 YS Incorrect material

specification.

2 FEA

Free body diagrams

Surro ate mechanisms

2 32

8 YS Incorrect use abuse

loadings specified

2 For finger use levers -

150 N For

hand use levers - 250

N Surrogate

2 32

9 General/Seatsystem to

resist

excessive

freeplay

Seat system does notresist excessive

freeplay

Customerexperiences some

disatisfaction

5 Front seat back fore/aftmovement - recliner

heart

2 T2000 heart. 4 fixngsof recliner to track

system - 5 dr. Latch

type claw Surrogate

mechanism

2 20

5 4 way linkage

mechanism

3 Reduce freeplay at

eack pivot location.

Rear lift system with

frre pivot at front.

Single likage system to

reduce interfaces.

Tolerance study.

Surrogate mechanism

2 30

10 Comfort/Seat

system to

provideadequate

suspension

and support.

System does not

provide adequate

supension and support.

Customer

dissatisfaction.

7 YS Loss of cushion

support

2 Dead pan design

90 mm Foam depth

under H point at centreline.


Customer sign off.

JCI knee test -

simulate user kneeing

on cushion facing rear

of seat.

Pressure mapping.

2 28



8/29

POTENTIAL


(DESIGN FMEA)





C Potential O D




ments s r c

7 YS Incorrect package. 3 Layout study.

Customer sign off.

Packaging issues list.

Pressure mapping.

Rear occupant foot

zone profile - 25 mm

clearance to underside

of pan.

2 42

7 YS Loss of FSB

suspension mat

support

3 Clip suspension mat

direct to frame

2 42

Occupant

discomfort

6 YS Incorrect A surface

design.

2 JCI design guidelines.


Customer sign off.

2 24

6 YS Loss of specified H

point, back angle, thigh

angle, heel point.

3 JCI knee test -

simulate user kneeing

on cushion facing rear

of seat.

H pt on complete seat

dwg.

2 36

6 YS Incorrect foam

hardness specified

3 Foam hardness,

density and weight tobe monitored. Link with

H-point checks

2 36

11 Comfort/Seat

system

provides an

optimum

pressure

distribution and

support.

System does not

provide optimum

pressure distribution

and support.

Customer

experiences some

disatisfaction

5 Incorrect A surface

design

3 Customer sign off on

ergonomic curves.

Pressure mapping.

2 30



9/29

POTENTIAL


(DESIGN FMEA)





C Potential O D




ments s r c

5 Incorrect Foam

specification

3 JCI design guidelines.


Customer sign off.

Pressure mapping.

2 30

5 Incorrect location of B

surface on FSC and

FSB

3 Pan B surface to be 90

mm from A surface

under H point at seat

centre linePrressure map test

Meat to metal

clearance to be min 30

mm

2 30

12 Comfort/seat

system

provides

adequate

movement and

adjustment.

System does not

provide adequate

movement and

adjustment.

Customer

experiences some

dissatisfaction.

5 Incorrect package

specification.

3 Seat slide travel 150

mm forward, 60 mm

rearward.

Height adjust range +/-

20 mm rear lift

Back angle design

position 25 deg,

rearward from vertical,

+/- 15 deg min for

comfort (larger angle

posible for additionalpackage requirements)

Track angle 2 deg

Height adjust lever

swing +/- 20 deg from

start position

Towel bar swing 10

deg from start position

System design

specification.


2 30



10/29

POTENTIAL


(DESIGN FMEA)





C Potential O D




ments s r c

13 Comfort/Syste

m to provide

sufficient

vertical travel

System does not

provide sufficient

vertical travel.

Customert

experiences some

dissatisfaction.

5 Incorrect design. 3 Engineering issues list.

Customer sign off.

2 30

System

ergonomically

unsuitable for

occupant.

5 Incorrect design. 3 JCI design guidelines.


Customer sign off.

2 30

Occupant

discomfort

6 YS Incorrect design. 3 JCI design guidelines.


Customer sign off.

2 36

14 Comfort/Syste

m to provide

sufficient

recline

adjustment.

System does not

provide sufficient

recline adjustment.

Occupant

discomfort

6 YS Incorrect location of

end stops

3 Design position 25 deg

rearward of vertical.

Min comfort adjustment

range +/-15 deg about

design position.

Package review

Additional package

adjustment for

horizontal rearward

condition. (Seat fore aft

position can be forwardof design in vehicle to

prevent clash with rear

seat cushion)

2 36

6 YS Lower edge of front

seat back interfeance

with rear of cushion

when reclined

rearward. (Condition

worst when cushion is

raised to highest

vertical position)

4 Soft to soft interfance

with structure having

min40 mm clearance

between sweep paths.

(Trim bulging -

appearance affected.

Degree determined by

biteline overlap)

3 72



11/29

POTENTIAL


(DESIGN FMEA)





C Potential O D




ments s r c

15 Comfort/Syste

m to provide

sufficient

headrest

adjustment.

System does not

provide sufficient

headrest adjustment.

Occupant

discomfort

6 YS Incorrect noth location

specified

3 Package review 2 36

Does not meet

legal height

9 YC Incorrect package

location

3 ECE 17 2 54

16 Comfort/Seat to

provide

adequate

ingress -

egress

clearance.

Seat does not provide

adequate ingress -

egress clearance.

Customer

experiences some

dissatisfaction.

5 Track infringment into

rear footwell

3 Reduced length

outboard lower track

section

Customer sign off.


Package checks.

3 45

5 Recliner cover/valance

infringement into

occupant path

3 Tailor plastic covers

close to structure. Min.

structure to be

determined.

Customer sign off.


Package checks.

3 45

17 Comfort/Seat

system toprovide good

ergonomic

position


provide goodergonomic poition.

Customer

experiences somedissatisfaction.

5 Incorrect H point, heel

point, back anglespecifed

3 Fiat approved

packaging details

2 30

5 Towel bar release

system incorrectly

positioned

3 Min 20 mm clearance

under lever to vehicle

carpet over front cross

member.

Jury evaluation for

reach

3 45



12/29

POTENTIAL


(DESIGN FMEA)





C Potential O D




ments s r c


incorrectly positioned

3 Jury evaluation for

reach

Fiat package and

styling review

3 45

18 Comfort/Seat

system to

provide

optimum

pressures

distribution for

long term

comfort.


provide optimum

pressures distribution

for long term comfort.

Customer

experiences some

dissatisfaction.


profile

3 Presssure map

A surface profiles

generated from

surrogate andbenchmark data

2 30

5 Uncorrect B surface

location of Pan and

FSB suspension mat

3 FSC - 90 mm foam

depth under H point at

centre line of seat

Pressure map test

2 30

5 Incorrect foam

specification

3 Pressure map test

Component FMEA

control of foam

hardness, density and

weight.

2 30

5 Incorrect trim tension 3 Pressure map testCombine with baggy

seat test evaluation.

2 30

5 Incorrect meat to metal

clearances

3 Min 30 mm

Package sections

Pressure map test

2 30

5 Incorrect seat system

adjustment

2 Fiat agreed adjustment

ranges.

Forward - 150 mm

Rearward - 60 mm

Vertical - +/- 20 mm

Recline - min +/- 15

2 20



13/29

POTENTIAL


(DESIGN FMEA)





C Potential O D




ments s r c

19 Comfort/Seat

system to

provide lifetime

comfort.


provide lifetime

comfort.

Customer

experiences some

disatisfaction

5 Foam collapse 2 Component FMEA to

identify controls.

ST-0036 followed by

pressure map and

Durability test

4 40

Loss of primary

function of FSC

8 YS Suspension system

collapse

3 Durability test

Dead pan FSC

2 48

20 Comfort/Seat

system to

provide

adequate meat

to metal

clearance


provide adequate meat

to metal clearance

Occupant

dissatisfaction.

6 Incorrect location of

structure

3 Min 30 mm meat to

metal

2 36

21 Appearance/Se

at system to

provide no or

consistant

gaps at

component/sub

system

interfaces


provide no or

consistant gaps at

component/sub system

interfaces

Defect noticed by

most customers

4 Incorrect profiles

specified

5 Customer sign-off

Eval 1 - exercise to

involve measuring

consistency of gaps.

4 80

4 Incorrect mating ofcomponents/sub

systems

5 Interlock edges ofornamentation

Customer sign-off

4 80

4 Incorrect profile of FSB

top surface and

underside of headrest

asy

5 Angle top of FSB to car

line

4 80


profile mis-match with

5 Fiat styling review 4 80



14/29

POTENTIAL


(DESIGN FMEA)





C Potential O D




ments s r c

22 Appearance/Se

at system to

conceal

internal

materials.


conceal internal

materials.

Occupant some

dissatisfaction.

5 Visible foam at base of

FSB - recliner region

5 Lower J retainer to

run full length of FSB

Customer sign off.

4 100

5 Visible recliner

structure when FSB

reclined away from

4 Recliner cover to

feature return edges.

Customer sign off.

4 80

5 Seat structure visible

when flip up cushion is

in up position - in order

to access stowage

compartment

3 Stowage box to cover

slide mechanism

Paint cross tubes

3 45 Clip in trim co

system.

Stowage box

false profile.

5 Cabling system visible

in car line

3 Dedicated fixed cable

routing

2 30 Check for ca

visibility durin

operation.

Check for cab

with seat mou

vehicl in full p

5 Ornamentation

disengages from seat

system occupant

3 Pull out forces to be

specified to all

ornamentation

3 45



15/29

POTENTIAL


(DESIGN FMEA)





C Potential O D




ments s r c

23 Apearance/Seat

system to

provide wrinkle

free trim

condition.


provide wrinkle free

trim condition.

Occupant some

dissatisfaction.


styling.

5 Smooth transition

between contours.

Back up trim with foam

and structure as

necessary.

Rear of front seat

cushion on top face of

bolster to have positivecrowning from front to

rear.

Joggle depression to

be minimised.

4 100 Design guide

needed for fo

profiles to elim

wrinkle enduc

5 Incorrect trim pattern

profile.

5 Development loop

together with Foam

overbuild.

4 100

5 Incorrect material

selection

5 Fiat spec for fabric.

Build trials

3 75

5 Sew margins not

cosidered for seat

5 Tolerance study. 3 75

5 No alignment aids for

trim cover assembly to

structure

5 FSB - align headrest

holes with foam and

structure.

Alignment markers onhorizontal tie down.

Hog ring centre

position first.

4 100 FSC - centre

depression m

front and rear

cushion pan.FSC trim - no

sew tag to de

centreline fron

alignment fea

Investigate so

attachments o

strip on FSB t

backframe



16/29

POTENTIAL


(DESIGN FMEA)





C Potential O D




ments s r c

5 Unsupported trim 5 FSB - lower J to run full

length across seat.

Back up trim with

sufficient foam

(overbuild as

necessary) and

structure.

4 100

24 Appearance/Seat system to

provide

ingress/egress

durability

Seat system does notprovide ingress/egress

durability

Fabric wearthrough - defect

noticed by most

customers

4 Incorrectmaterial/pattern/foam/s

eam specification

3 JCI ingress-egress test 4 48

25 Appearance/Se

at system to

provide a tight

fitting cover

prior to use.


provide a tight fitting

cover prior to use.

Fabric bridging

foam - defect

noticed by average

customers

3 Concave foam profile 3 5mm crowning on

surfaces within contact

with occupant

Blunt hog ring to

prevent variability in

trim tension during

assembly process

4 36

3 Excess material 3 Prototype builds and

evaluation

4 36


provide a tight

fitting cover

after use.

Seat system does notprovide a tight fitting

cover after use.

Defect noticed bymost customers

5 Baggy/saggy trim cover 5 Durability tests 2 50

4 Baggy map pocket 4 Plastic strip along top

edge sewn into cover.

Trim retention along

complete lower egde of

FSB

3 48



17/29

POTENTIAL


(DESIGN FMEA)





C Potential O D




ments s r c

27 Appearance/Se

at system to

prevent visible

thread ends


prevent visible thread

ends

Defect noticed by

average customers

3 Incorrect seam design 3 Control plan for sewing 6 54

28 Apearance/Seat

system to

prevent readthrough on A

surface


prevent read through

on A surface

Defect noticed by

most customers


selection.

3 Min. 4 mm laminate

fabric

High loft or scrimbacked vinyl not to be

used over foam tool

split lines/channels

4 48

4 Incorrect foam profiles 3 Styling sign off from

Fiat

4 48

4 Foam tail on fsb wraps

around lower cross

member of FSB

structure. Produces

sharp edge over which

fabric runs.

4 Top rear tie down only.

Lower J at lowest point

on FSB

Prototype builds

3 48

19 Appearance/Se

at system to

provide

acceptable trimseam

appearance


provide acceptable trim

seam appearance

Customer

dissatisfaction.

4 Split seams during

assembly

3 Prototype builds 4 48

4 Split seams during

customer useage

4 Control plan for sewing 4 64

30 Apearance

/Seat system to

provide design

intent colours.


provide design intent

colours.

Customer

dissatisfaction.

4 Incorrect colour shade

tolerance specified

3 Boundary samples

derived

Light box Customer

sign off - Design

studio.

Fiat issued colour

8 96


selection.


Build trials

4 32



18/29

POTENTIAL


(DESIGN FMEA)





C Potential O D




ments s r c

31 Apearance

/Seat system to

provide design

intent colours

after design life

of vehicle.


provide design intent

colours after design life

of vehicle.

Customer

dissatisfaction.


selection.


Build trials

4 32


provide

required styling

Seat system does notprovide required

styling.

Customerdissatisfaction.

4 Incorrect design. 3 STO lines approvalPrototype Builds

Styling Reviews

2 24

4 Incorrect Trimmed A

surface

4 STO vs scan line

analysis

3 48

4 Doming of top of seat

back between headrest

bezels

4 Localised overbuild of

foam around bezel

apertures.

Salvage groove at

centre line to

accommodate trim

seams

Review for prototypes

3 48

33 Appearance/Se

at system to

provide

resistance to

seat cover

soiling.


provide resistance to

seat cover soiling.

Customer

dissatisfaction.


selection.

2 Fiat spec for fabric,

Fleet evaluation

4 32 JCI to inform

material selec

program stain

improve vehic

resistance.



19/29

POTENTIAL


(DESIGN FMEA)





C Potential O D




ments s r c

34 Appearance/Se

at system to

provide

adjustment

controls in

design position

prior and after

use


provide adjustment

controls in design

position prior and after

use

Customer

dissatisfaction.

5 Sticking height adjust

lever

4 Balanced 3 point fixing

of lever to clutch mech.

Return spring

operating aroung

mechanism centre line.

Clearance of 5 mm

between lever and

valance.Eval 1

3 60

4 Sticking track release

lever

2 Return spring on lever

Tolerance study for

free movement of lever

to housing

2 16

35 Seat system to

provide a

system free of

BSR


provide a system free

of BSR

Defect noticed by

most customers

4 Excessive freeplay in 4

way height adjust

system

4 Tolerance study

Reduce linkage

interfaces

Pre-tension system

with assist spring.

Bush pivot points as

necessary

3 48


contact with valance

induced by vibration

3 3 point retention of

handle to mechanism

Distance of handle freeend to valance Min 10

mm

2 24

4 Excessive freeplay in

Flip up cushion system

5 Tolerance study

Reduce linkage

interfaces

3 60


fsb system

4 Clamp 5 dr version at

front with M10 to

torque 45 - 50 Nm

3 48



20/29

POTENTIAL


(DESIGN FMEA)





C Potential O D




ments s r c


headrest system

4 Plunge apertures in

FSB frame at top and

bottom locations

Divorce bezel latching

into frame from stem.

Button system on one

side of stem only

3 48

4 Foam squeak againstmetal structure

4 Flat surface interactionCorovin with location

aids in Fsb

Size for size foam

agaist structure

3 48

4 Return spring vibration

form use and/or forced

excitation

4 Sleeve springs

Angle claw ends to lift

spring away from

adjacent component

edges

3 48

4 Recliner transmission

rod freeplay within

recliner heart

4 Plastic insert in recliner

heart

3 48

4 FSB suspension mat

contact with frame

4 Lock top fixing into

frame with pre-load

Clearance of mat toframe through

movement

3 48

4 Track release wire

contact against

adjacent components

3 Tubular towel bar

system with integral

torque tube and end

stops. (Pre-loaded

tension)

3 36

4 Seat resonance 3 Vibration platform test 3 36

4 Track misalignment

resulting scrapping

noise during fore/aft

movement

3 Foot print tolerance

control SC on

GD & T controls Seat

build fixtures to align

with datum controls

4 48 Vehicle body

agreement wi



21/29

POTENTIAL


(DESIGN FMEA)





C Potential O D




ments s r c

4 User adjustment lever

rub against vinyl trim

4 Vinyl not to be

specified against

moving plastic handle

or ornamentation

3 48

36 Efforts/Seat

system to

provide

acceptablerecline efforts


provide acceptable

recline efforts

Customer

dissatisfaction.

7 YS Friction,

misalignments,

incorrect geomety

specified

4 Recliner lever effort

Max. 4 Nm. (Update

requirement with JCI

target of 2 - 3 Nm. (SC4 fwd -15 deg to + 15

deg. SC 5 rwd + 15

deg to -15 deg. Both

taken either side of

design posn)

Recliner heart torque

0.9 Nm max

GD&T with common

datum for fixing

locations Width

across assembled seat

at front marriage = 439

+/-1mm SC4(FSB dwg)

Foot print control.

Document footprint

tolerance on complete

3 84

7 YS Uneven floor mounting

in vehcle specified

5 Foot print control.

Document footprint

tolerance and

mounting sequence on

complete seat

4 140

7 YS User hand clearance

intrusion from centre

console

5 Provide 60 mm

clearance zone around

hand wheel.

Buck package trials

Agreement with Fiat if

less than 60.

3 105



22/29

POTENTIAL


(DESIGN FMEA)





C Potential O D




ments s r c

7 YS User di ficul ty in

activating due to

incorrect size of

handwheel

3 Use diameter of 80 mm

max

2 42

37 Efforts/Seat

system to

provide

acceptableheight adjust

efforts


provide acceptable

height adjust efforts

Customer

disatisfaction

7 YS Incorrect mechanical

advantage

3 Free body diagram

calculations.

Use assist spring if

necessary. JCItarget of 65 +/- 20 N

2 42

7 YS Misalignment of track

system

4 Foot print tolerance

control

3 84

38 Efforts/Seat

system to

provide

acceptable

track sliding

efforts


provide acceptable

track sliding efforts

Customer

disatisfaction

7 YS Friction,

misalignments,

incorrect geomety

specified

4 Individual slide effort

15 - 50 N Slide

parallelism 2 mm

Bolting sequence to

body - As agreed with

Fiat

(Torque 24 - 28 Nm,

M8 fixing)

Track angle 2.0 deg.

Foot print tolerance

control

2 56

7 YS Uneven floor mounting

in vehcle specified

5 Foot print control.

Document footprint

tolerance and

mounting sequence on

complete seat

4 140

7 YS Package angle too

steep

4 Packaging checks

package angle 2.0 deg.

2 56

7 YS Seat weight 2 Target weight lower

than existing seat

2 28



23/29

POTENTIAL


(DESIGN FMEA)





C Potential O D




ments s r c

39 Efforts/Seat

system to

provide

acceptable

track handle

efforts


provide acceptable

track handle efforts

Defect noticed by

most customers

4 YS Incorrect

geometry/misalignment

tolerance specified.

Incorrect spring rates

specified

3 Free body diagram

calculations.

(handle effort 10-65 N.

JCI target 50 +/- 15N

Slide trigger spring rate

Seat foot print

tolerance documented

on complete seatdrawing.

Vehicle floor body

tolerance agreement

with Fiat. Vehicle plant

to record dimensional

data on mounting

locations between seat

and vehicle body

Provide min 35 mm

between handle bar

and vehicle floor

2 24

40 Efforts/Seat

system to

provide

acceptableheadtrest

adjust efforts


provide acceptable

headrest adjust efforts

Customer

experiences

discomfort

6 SC Tolerance stack up of

frame, bezel, stem and

button spring rate.

4 Plunge top and bottom

holes in FSB frame.

Latch bezel into frame

with inner latch faceaway from running

surface with rod.

Prevent bulging around

notch profiles.

Control button spring

efforts. target of 55 +/-

20 N

6 144



24/29

POTENTIAL


(DESIGN FMEA)





C Potential O D




ments s r c

41 Efforts/Seat

system to

provide

acceptable flip

up cushion

release and

closing efforts


provide acceptable flip

up cushion release and

closing efforts

Customer

experiences

discomfort

6 SC Incorrect geometry 3 Kinematic study,

Surrogate system

4 72

6 SC Incorrect latch

retention specified

3 JCI target effort 40 +/-

15 N

6 108

42 Handling/Seat

system to

provide

adequate

handling

locations


provide adequate

handling locations

Difficulty in

handling the seat

5 Sharp edges 4 Safe edge/de-burred

edges in potential lift

areas

2 40

5 Seat interferes with

vehicle door aperture

2

Package/manufacturin

g review - Fiat

2 20

43 Serviceability/S

eat system to

permiteconomic

servicing


permit economic

servicing

High replacement

costs

5 Headrest not

removable

3 Bezel button with stem

notch detent -

dedicated useroperation to remove

Fiat workshop manual

review

2 30

5 Headrest bezel not

removable

3 Feature on bezel to aid

removal.

Fiat workshop manual

review

2 30

5 Trim covers not

removable

3 Fiat workshop manual

review

2 30

5 Plastic covers not

removable


review

2 30 Investigate m

releasing recl

handwheel wi

damage.



25/29

POTENTIAL


(DESIGN FMEA)





C Potential O D




ments s r c

5 FSB not removable

from tracks


review

2 30

44 Corrosion

resistance/Seat

system to

resist oxidation

of visible

materials andstructure in

water ingress

regions


resist oxidation of

visible materials and

structure in water

ingress regions

Appearance

compromised.

Defect noticed by

most customers.

4 Unpainted/plated

structure

3 Paint visible structure

Headrest stems to be

plated

2 24

Structual integrity

compromised

10 YC Unpainted/plated

structure

5 Paint slide assemblies 6 300

45 Seat system to

permit

attachment to

vehicle


permit attachment to

vehicle

Cannot attach seat

to vehicle

8 SC No attachment feature

on seat

2 Four off feet to accept

M8 fixing into body.

Location pin in front

feet

2 32

8 SC Incorrect package

specified

2 Package review

Foot print control.

Document footprint

tolerance on complete

seat drawings

2 32

46 Efforts/Seat

system to

provide

acceptable

headrest button

efforts


provide acceptable

headrest button efforts

Customer

experiences

discomfort

6 YS Incorrect spring rate

and/or sliding

clearances specified

3 Control plan for

individual components,

Surrogate system

2 36

47 Feature/Seat

system to

provide

underseat

stowage


provide underseat

stowage

Defect noticed by

most customers

4 No/incorrect

mechanism specified

for flip up seat.

5 BOM for component

release

Functional builds

CAD kinematics

Package checks

3 60



26/29

POTENTIAL


(DESIGN FMEA)





C Potential O D

te Item Potential Potential S l Cause(s)/ c Current e R. Recomme

# Function/ Failure Effect(s) of e a Mechanism(s) c Design t P. Action


ments s r c

4 No stowage box

specified.

3 BOM for component

release

Functional builds

Package checks

3 36



27/29

Process Failure Mode Effects and Analysis (PFMEA) Instructions

NOTE: Process FMEA's must be prepared for all programs (components, subassemblies and assemblies)

where Johnson Controls has full program design responsibility. (A matrix for this purpose and the FMEA

Form can be found in the AIAG APQP and Control Plan manual).

INSTRUCTIONS:

1. Process FMEA's are to be prepared using the DaimlerChrysler, Ford, and General Motors guidelines.

2. All operations affecting fit, function, durability, governmental regulations and safety must be identified and

listed sequentially.

3. Similar part FMEAs must be considered.

4. Historical campaign, warranty data, high mileage and P-diagram data must be reviewed.

5. Appropriate corrective actions must be planned and/or taken for high risk priority items (RPN 70 and

greater).

6. Appropriate corrective actions must be planned and/or taken for high severity numbers (severity of 7 and

greater).

7. Risk priorities numbers must be revised when corrective actions are completed.

8. High severity numbers must be revised when a design change is completed.

9. The effects must consider the customer in terms of the subsequent operation, assembly, and product.

10. Warranty information must be used as an aid in developing the Process FMEA.

11. Customer plant problems must be used as an aid in developing the Process FMEA.

12. The causes must be described in terms of something that can be fixed or controlled.

13. Where detection is the major factor, provisions must be made to control the cause prior to the next

operation.

14. The PFMEA must identify and address all Special Characteristics (both significant and critical).

WW-PLUS-FR-04-31-E / Rev 01 Page 27 of 29


28/29

POTENTIAL


(PROCESS FMEA)

Item: Process Responsibility:

Model Year(s)/Vehicle(s) __________________________ Key Date

Team:

C Potential O D

Process Process Potential Potential S l Cause(s)/ c Current e

# Function/ Failure Effect(s) of e a Mechanism(s) c Process t

Require- Mode Failure v s of Failure u Controls e

ments s r c



29/29

Customer and Internal Special Char. Symbols

North American Interiors ~Internal SC symbol

Shield - DaimlerChrysler

Safety Compliance - GM

Diamond - DaimlerChrysler

Pentagon - DaimlerChysler

CC or YC Critical Characteristic - Ford

Fit/Function - Ford

SC or YS Significant Characteristic

Documents

221859366 f169 Dfmea Front Strip System 01feb2001