,D-FMEA,,,,(DESIGNFMEA),,,,,,,,,,,,,,

,,,,,,System,,Subsystem,,,Component,,,,,,,,

,,,,,,,,,,,,,,,,,,,,

,PartNo.,,Partname,,,Drawing(No.&issue),,,,Customer,,,FMEA(No.&issue),,,,,,

,SeeDWG#,,SeatHeater,,,"AE9A-14D698-BA,AE9A-14D696-BA",,,,,Ford,,B01,,,,,,

,Project(No.&name),,,,,Keydate(finishdate),,Date(firstissue),,Date(thisrevision),,,S-Severity/Allvarlighetsgrad,,,,,,

,,U39200D4722ndRow,,,,,,,4-18-2008,4-18-2008,,,O-Occurency/Felintensitet,,,,,,

,Issuedby,,,Dept./BA,,Participants(thisrevision),,,,,,,D-Detection/Uppt?cktssannolikhet,,,,,,

,,J.Saputo,,Engineering,,"JSA,STZI,SCO",,,,,,,RPN-RiskPriorityNumber/Risktal,,,,,,

,,,,,,,,,,,,,,,,,,,,

,PART/FUNCTION,,CHARACTERISTICSOFPOTENTIALFAILURES,,,,,,CONTROL,,,ACTION,,,RESULT,,,,

,Pos,Partname,Potential,Potential,,(KPC),Potential,,Prev./Detection,,,,,Estimated,Performed,,,,

,No.,anditsfunction,Failuremode,Effectoffailure,S,Class,Causesoffailure,O,Control(current),D,RPN,Action,Resp.,Date,Date,S,O,D,RPN

,,,,,,,,,,,,,,,,,,,

,1,HeatSystem,,,,,,,,,,,,,,,,,

,,Tostoptheheatlossfromaperson.,Insufficientpowerallocated,Incorrectheatperformance,5,,Incorrectpowerspecified,4,Perf.test905052,1,20,,,,,,,,

,,,Toocold,Incorrectheatperformance,5,,Inadequateheatcalculation,4,Perf.test905052,1,20,,,,,,,,

,,,Badheatfunction,Incorrectheatperformance,5,,Elementdesign&controlunit,4,Perf.test905052,3,60,,,,,,,,

,,,,Noheat,6,,BodyHarnessfailure,4,Customerspec.,5,120,CustomerDFMEA/DV/PVTesting,FORD,,,6,2,2,24

,,,,NoHeat,6,,Wrongcircuitinformation,4,Perf.test905052oncompleteseat,1,24,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,,Togivethecustomerapleasantseatcomfort.,Wrongpowerdistribution,Incorrectheatperformance,5,,Inadequateheatcalculation,3,Perf.test905052,1,15,,,,,,,,

,,,Insufficientpowerallocated,Incorrectheatperformance,5,,Incorrectpowerspecified,4,Perf.test905052,3,60,,,,,,,,

,,,Toohot,Incorrectheatperformance,5,,Inadequateheatcalculation,4,Perf.test905052,3,60,,,,,,,,

,,,Toocold,Incorrectheatperformance,5,,Inadequateheatcalculation,3,Perf.test905052,1,15,,,,,,,,

,,,Badheatfunction,Incorrectheatperformance,5,,Elementdesign&controlunit,3,Perf.test905052,2,30,,,,,,,,

,,,,Unregulatedsystem,7,,Controlmodulefailure,4,Informcustomer,6,168,InformcustomertoincludeitincontrolmoduleDFMEA,,,,7,2,2,28

,,,,Noheat,6,,SeatHarnessfailure,4,Perf.test905052,1,24,,,,,,,,

,,,,Unregulatedsystem,7,,Wrongcircuitinformation,3,Perf.test905052,1,21,,,,,,,,

,,,Toostiffheaterpad,Badseatcomfort,2,,Incorrectmaterialspecified,1,Perf.test905052&Customertesting,5,10,,,,,,,,

,,,Emitsfumes,Unpleasantodor,2,,Incorrectmaterialspecified,1,TRtest905331,2,4,,,,,,,,

,,,,Fogging,2,,Incorrectmaterialspecified,1,Fogging905310test,3,6,,,,,,,,

,,,Excessivewear,Lowerheatingpower,5,,Heatingwirepartiallybroken,3,Endur.905051,2,30,,,,,,,,

,,,,Noheat,6,,Heaterwirebroken,3,Endur.905051,2,36,,,,,,,,

,,Visualappearance,Shrinks,Elementdimensionoutofspec,6,,Incorrectmaterialspecified,1,TRtest905331,2,12,,,,,,,,

,,,Materialtoostretchy,Elementdimensionoutofspec,6,,Incorrectmaterialspecified,1,TRtest905331,2,12,,,,,,,,

,,,Toothickpad,Elementdimensionoutofspec,6,,Incorrectmaterialspecified,1,TRtest905331,2,12,,,,,,,,

,,,Toothinpad,Elementdimensionoutofspec,6,,Incorrectmaterialspecified,1,TRtest905331,2,12,,,,,,,,

,,,Wear,Wrinkles,6,,Unspecifiedtrim-cover,2,Endur.905051,2,24,,,,,,,,

,,,,Heatingwirereadthrough,2,,Unspecifiedtrim-cover,2,Endur.905051,2,8,,,,,,,,

,,,Discoloursurroundingmaterial,Destroyedtrimcover,4,,Incorrectmaterialspecified,1,Endur.905051/21395,5,20,,,,,,,,

,,,,Visualeffectontrimcover,5,,Incorrectmarkingink,1,Endur.905051/21395,5,25,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,2,Topfeltlayer,,,,,,,,,,,,,,,,,

,,Tocarrytheheatingwire.,Feltseparation,Reducedheat,5,,Incorrectmaterialspecified.,1,Endur.905051/21395,3,15,,,,,,,,

,,,,Noheat,6,,Incorrectmaterialspecified.,1,Endur.905051/21395,3,18,,,,,,,,

,,,Shrinks/Stretch,Outofspecdimensions,6,,Incorrectmaterialspecified.,1,"TR905331/

Endur.21395",3,18,,,,,,,,

,,,Destructionbychemicals,Brittlematerial,7,,Chemicalsspilledonseat,1,TR905331,5,35,,,,,,,,

,,,,Dimensionsoutofspec,6,,Chemicalsspilledonseat,1,TR905331,5,30,,,,,,,,

,,,DestructionbyUV,Brittlematerial,7,,Exposuretodirectsunlight,1,Materialspec,5,35,,,,,,,,

,,,,Dimensionsoutofsped,6,,Exposuretodirectsunlight,1,Materialspec,5,30,,,,,,,,

,,,Destructionbyhightemperature,Brittlematerial,7,,Incorrectmaterialspecified.,1,TR905331,1,7,,,,,,,,

,,,,Dimensionsoutofspec,6,,Shrinkage,1,TR905331,1,6,,,,,,,,

,,,Destructionbylowtemperature,Brittlematerial,7,,Incorrectmaterialspecified.,1,TR905331,1,7,,,,,,,,

,,,Wear,Damagedmaterial,6,,Incorrectmaterialspecified.,2,Endur.905051/21395,3,36,,,,,,,,

,,Tocovertheheatingwire,Toothin,Heatingwirereadthrough,2,,Incorrectmaterialspecified.,1,Endur.905051/21395,5,10,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,3,Laminatinggluelayer,,,,,,,,,,,,,,,,,

,,Tolaminatetopandbottomfelt,Delaminationoftopandbottomfelt,Wrinklesbetweentopandbottomcarrier,6,,Incorrectmaterialspecified.,2,"Endur.905051/21395

TR905331",2,24,,,,,,,,

,,,,Heatingwiremoves,7,,Incorrectmaterialspecified.,2,"Endur.905051/21395

TR905331",2,28,,,,,,,,

,,,Destroyedbyhigh/lowtemperature,Delamination,7,,Incorrectmaterialspecified.,2,"Endur.905051/21395

TR905331",2,28,,,,,,,,

,,,Destroyedbychemicals,Delamination,7,,Incorrectmaterialspecified.,1,TRtest905331,5,35,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,4,Heatingwire,,,,,,,,,,,,,,,,,

,,Togenerateheat,Breakage,Reducedheat,5,,Fatigue,2,Endur.905051/21396,2,20,,,,,,,,

,,,,Noheat,6,,Damagedwire,2,Endur.905051/21396,2,24,,,,,,,,

,,,Corrosion,Reducedheat,5,,Destroyedbychemical,1,TR905331,3,15,,,,,,,,

,,,,Noheat,6,,Destroyedbychemical,1,TR905331,3,18,,,,,,,,

,,,ToHot/ToCold,Incorrectheatperformance,5,,Incorrectelementdesign,3,Performance905052,2,30,,,,,,,,

,,,HeatUnballance,Incorrectheatperformance,5,,Incorrectelementdesign,3,Performance905052,2,30,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,5,Bottomfeltlayer,,,,,,,,,,,,,,,,,

,,Toprotecttheheatingwireandtoimprovelamination.,Feltseparation,Reducedheat,5,,Incorrectmaterialspecified.,2,Endur.905051/21395,3,30,,,,,,,,

,,,,Noheat,6,,Incorrectmaterialspecified.,2,Endur.905051/21395,3,36,,,,,,,,

,,,Shrinks/Stretch,Outofspecdimensions,6,,Incorrectmaterialspecified.,2,"TR905331/

Endur.21395",3,36,,,,,,,,

,,,Destructionbychemicals,Brittlematerial,7,,Chemicalsspilledonseat,1,TR905331,5,35,,,,,,,,

,,,,Dimensionsoutofsped,6,,Chemicalsspilledonseat,1,TR905331,5,30,,,,,,,,

,,,DestructionbyUV,Brittlematerial,7,,Exposuretodirectsunlight,1,Materialspec,5,35,,,,,,,,

,,,,Dimensionsoutofsped,6,,Exposuretodirectsunlight,1,Materialspec,5,30,,,,,,,,

,,,Destructionbyhightemperature,Brittlematerial,7,,Incorrectmaterialspecified.,1,TR905331,2,14,,,,,,,,

,,,,Dimensionsoutofspec,6,,Shrinkage,1,TR905331,2,12,,,,,,,,

,,,Destructionbylowtemperature,Brittlematerial,7,,Incorrectmaterialspecified.,1,TR905331,2,14,,,,,,,,

,,,Wear,Damagedmaterial,6,,Incorrectmaterialspecified.,2,Endur.905051/21395,3,36,,,,,,,,

,,Tocovertheheatingwire,Toothin,Heatingwirereadthrough,2,,Incorrectmaterialspecified.,1,Endur.905051/21395,5,10,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,6,Adhesiveinstripes,,,,,,,,,,,,,,,,,

,,Adhesivetofastenheatingelement,Destructionbychemicals,Comeloosefromfoambun,7,,Incorrectmaterialspecified.,1,TRtest905331,5,35,,,,,,,,

,,,DestructionbyHigh/Lowtemperature,Comeloosefromfoambun,7,,Incorrectmaterialspecified.,1,TRtest905331,2,14,,,,,,,,

,,,Destructionbyhumidity,Comeloosefromfoambun,7,,Incorrectmaterialspecified.,1,TRtest905331,2,14,,,,,,,,

,,,,,,,,,,,,,,,,,,,,

,7,Cableharnesssystem,,,,,,,,,,,,,,,,,

,,Todistributepowerandcontrolsignals.,Shortcircuit,Unregulatedsystem/moduledetectfailure,8,,Cutbysharpmetaledgeconnectedtoground,2,Cust.Resp.,3,48,,,,,,,,

,,,Opencircuit,Noheat,6,,Specifiedcabletoshort/wear,3,Cust.Resp.,3,54,,,,,,,,

,,Insulatingtube-Toprotectandtoholdcableharnesstogether,Tooshort,Reducedabilitytoholdcableharnesstogether,3,,Incorrectlengthspecified,2,Designreview,2,12,,,,,,,,

,,,Wear,Reducedabilitytoholdcableharnesstogether,3,,Wrongharnessrouting,2,Cust.Resp.,3,18,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,8,Meltglue,,,,,,,,,,,,,,,,,

,,Toreliefharnessandheatingwireandtoprotectsolderjoints.,Pooradhesiontoharnesswires,Nostrainrelief,5,,Incorrectmaterialspecified,2,TRtest905331,3,30,,,,,,,,

,,,Largemeltgluespots,Destroyeddesign(visual),2,,Toomuchgluespecified,2,TransferedtoDrawing,3,12,,,,,,,,

,,,Gluemelting,Nostrainrelief,5,,Incorrectmaterialspecified,2,TRtest905331,3,30,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,9,Solder,,,,,,,,,,,,,,,,,

,,Toestablishelectricalcontact,Opencircuit/Poorconnection,Noheat,6,,Wrongsolderspecified,1,"Designreview

TR905331",3,18,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,10,Terminals,,,,,,,,,,,,,,,,,

,,"Toconnect

betweencables.",Loosenfromconnector/housing,"Opencircuit,noheat",6,,Incorrectmaterialcombination,2,"Designreview

TR905331",2,24,,,,,,,,

,,,Reduceharnesspulloffforce,"Opencircuit,noheat",6,,Incorrectsizedterminal,2,"Designreview

TR905331",2,24,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,11,"Connector/

housing",,,,,,,,,,,,,,,,,

,,Toprotectterminalsandsecurecontactbetweencables.,Terminalsmisplacedinhousing,"Opencircuit,noheat",6,,Incorrectspecifiedondrawing,2,"Designreview

Perf.905052",2,24,,,,,,,,

,,,,Increasetheeffectofashortcircuitfailure.,8,,Heater+andheater-aremisplacedondrawing,2,"Designreview

Perf.905052",2,32,,,,,,,,

,,,Terminalloosenfromhousing,Noheat,6,,Secondarylockloosen,1,"Designreview

TR905331",2,12,,,,,,,,

,,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,12,Marking,,,,,,,,,,,,,,,,,

,,Toidentifyproductwithcompanydocumentation,Incorrectmarking,Incorrectlyidentifiyingpart,2,,Incorrectspecifiedondrawing,2,Designreview,3,12,,,,,,,,

,,,Markingnotondrawing,Incorrectlyidentifiyingpart,2,,Incorrectspecifiedondrawing,2,Designreview,3,12,,,,,,,,

,,,,,,,,,,,,,,,,,,,,

,13,SensorTemplate,,,,,,,,,,,,,,,,,

,,TocontrolthedistancebetweentheheatingwireandtheNTC,DistancebetweenNTC&heatingwireIncorrect,Incorrectheatperformance,5,,Incorrectspecifiedondrawing,4,"Performance905052

Designreview",2,40,,,,,,,,

,,Fixationofthermistor,Sensorispulledoutofposition,Incorrectheatperformance,5,,Incorrectstrainrelief,3,"Endur.905051/21396

DesignReview",3,45,,,,,,,,

,,,,,,,,,,,,,,,,,,,,

,14,NTCthermistor,,,,,,,,,,,,,,,,,

,,Tosenseelementtemperature,Incorrectheatperformance,Doesn'tmeetcustomerrequirement,5,,Wrongthermistorplacementondesign&highsetpoint,4,Performance905052,3,60,,,,,,,,

,,,,Doesn'tmeetcustomerrequirement,5,,IncorrectNT