ZF SACHS SUSPENSION MXICO S.A. DE C.V.

MANUFACTURING ENGINEERING
PART N.: NAME: PROCESS: No. 0 REAR & FRONT SHOCKS SHOCK FINAL ASSEMBLY FINAL ASSEMBLY CAMBIOS Issue Emission

PROCESS

FAILURE

FAILURE

E V C E L R A

FUNCTION / REQUIREMENTS

MODE

EFFECT

I S T S Y

Load Strut into pallet line Wrong shock absorber selected Strut loaded in wrong position Wrong tooling selected Improper side build Performance issues

Read bar code label on shock body

Can not assembly the module press Damage Strut Drop & damage shock during transportation No tracebility Troubles in data collection Missing label No traceability, no identification No readible label No traceability, no identification Incorrect position of label No traceability, no identification

Load Spring with Subassemblies onto Strut Assembly of Dust tube & Sprin seat upper with spring (TX6A) Bearing loaded upside down Missing bearing or double Missing spring seat upper Performance issue, damping. Client complain. Performance issue, damping. Client complain. Performance issue, damping. Client complain.

Assembly of Jounce Bumper, Missing Spring pad-clip Cover dust, Spring pad-clip with Spring seat upper (FIT) Jounce Bumper loaded upside down

Performance issue, damping. Client complain. Performance issue, damping. Client complain. Missing Jounce bumper Performance issue, damping. Client complain. Incorrect assembly of Noisy module assembly, lower isolator claint complain Missing lower isolator Noisy module assembly, claint complain Improper rod protection Improper rod protection Noisy module assembly, claint complain Performance issue, damping. Client complain. Performance issue, damping. Client complain. Performance issue, damping. Client complain. Cosmetic issue Client complain Cant not be assembled in car Cant not be assembled in car Cant not be assembled in car Performance issue, damping. Client complain. Low durability. Client complain Low durability. Client complain Performance issue, damping Cant not be assembled in machine Loose upper mount

Dust tube assy no placed properly. Missing dust tube assy Incorrect assembly of dust tube Manual assembly of spring Spring no placed properly. Incorrect spring

Spring loaded upside down Damage paint Module assembly Manual assembly of upper mount in upper tool (TX6A)

Upper mount assembly no placed properly. Missing upper mount assembly Load part placing the upper mount with incorrect angle Damage spring pad-clip

Manual assembly of upper bearing (FIT)

Miss upper bearing Bearing inverted Damage shock Strut misaligned

Manual assembly of nut

Wrong nut orientation

Miss nut Damage nut Miss tightening Improper torque Cross thread Unload module assy from pallet line Damage shock Damage paint

Loose upper mount Loose upper mount Loose upper mount Loose upper mount Loose upper mount

Automatic torque.

Performance issue, damping Cosmetic issue Client complain

S.A. DE C.V.

PROCESS FAILURE MODE AND EFFECT ANALYSIS

TEAM MEMBERS: Manufacturing SSM: Israel Iiguez +52 (33) 32080000 Ext.5062 Quality SSM: Maintenance SSM: Francisco Daz +52 (33) 32080000 Ext.2611 FECHA 3-Feb-12 C / E No.

D E

POTENTIAL FAILURE CAUSE APPLICATION

C U R R E N C E

CURRENT CONTROLS

T E C T I O N

R P N

PREVENTIVE

DETECT

Operator selects wrong parts Pallet & Tool design Wrong tool selected Pallet & Tool design Line design Label not placed on part Printer malfunction Label placed in wrong location

TX6A & FIT TX6A & FIT TX6A & FIT TX6A & FIT TX6A & FIT TX6A & FIT TX6A & FIT TX6A & FIT

Operator loads bearing upside down Operator mishandling

TX6A

TX6A Operator bypasses part TX6A

Operator mishandling FIT Operator loads jounce bumper upside down Operator mishandling TX6A Isolator placed wrong TX6A & FIT Operator bypasses operation Sub-assembly dust tube placed inverted Operator bypasses operation Dust tube placed wrong

TX6A

TX6A & FIT TX6A & FIT TX6A & FIT TX6A & FIT

Wrong alingned by the operator Spring selected wrong

TX6A & FIT

TX6A & FIT Operator loads spring upside down Pallet design

TX6A & FIT TX6A & FIT

Upper mount placed inverted Baypassed operation Load part into machine in wrong way Load part into machine in wrong way Baypassed operation Operator upper bearing washer upside down Tool design Machine design Operator loads nut upside down

TX6A TX6A TX6A

FIT FIT FIT TX6A & FIT TX6A & FIT TX6A & FIT

Operator bypasses operation Improper handling Machine malfunction Improper Set up of machine Improper handling

TX6A & FIT TX6A & FIT TX6A & FIT TX6A & FIT TX6A & FIT

Pallet design Pallet design

TX6A & FIT TX6A & FIT

N AMEFP-MOD1A

AUTHOR PROCESS RESP. PFMEA DATE:

Israel Iiguez Jose Manuel de la Cruz Marzo 2013 APROBO: J. M. de la Cruz

REALIZO: Israel Iiguez

S O D E C E

RECOMMENDED ACTIONS

ACTIV.

R P ACTIONS R R C N
V U T E R E I E T T N I Y C O E N

TAKEN

RESP.