POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS FMEA Number: Receiving

(PROCESS FMEA)
Prepared by: Core Team

Part: Raw materials & components Process Responsibility FMEA Date (Orig.) 2/10/2009

Model Year(s)/Program(s) N/A Key Date 2/10/2009 FMEA Date (Rev.) 6/2/2009

Core Team:

Process Action Results

Responsibility
Classification

Occurrence

Completion
Step Current Current

Detection

Occurrence
Severity
Potential Potential Potential

Detection
Target
Process Process Recommende

RPN

Severity
Date
Requirements Failure Effect(s) Causes(s) Actions Effective

RPN
Controls Controls d Action
Mode of Failure of Failure Taken Date
Prevention Detection
Function
10.a Verify Product free Damaged Significant 7 Product damaged in 2 Specified Visual 7 98 None
shipment & of damage product production transit carrier to evaluation
unload received delays; supplier prior to
deviation unloading
from primary
Shipment Supplier process 7 Supplier did not have 2 Quantity Visual 7 98 None
must match partial quantity avaialble inquiry prior to evaluation
bill of lading shipment order release after unloading

10.b Review Pallet labels Missing Significant 7 Inadequate labeling by 1 Labeling Visual 7 49 None
& receive and/or part product production supplier requirements evaluation of
shipment number on identification delays; specified to each box or
each deviation supplier container
container/box from primary
process
Lot number on Missing lot 7 1 7 49 None
each number
container or
box
Product Certification 7 Inadequate lot controls 2 Supplier Visual 7 98 None
certification for not included by supplier selection and evaluation of
each new lot w/ shipping performance each lot
(every lot for documents monitoring
outsourced process
product)

Product Product 7 2 7 98 None

certification certification
must match does not
product lot match product
numbers lot numbers

Label & Label & 7 Inadequate shipping 2 Visual 7 98 None

packing list packing list process controls by evaluation of
quantities quantities do supplier shipment &
must match not match shipping
papers
An open order There is no 7 2 Product 7 98 None
must exist for open order for received
the product the product against open
PO

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 POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS FMEA Number: Receiving
(PROCESS FMEA)
Prepared by: Core Team

Part: Raw materials & components Process Responsibility FMEA Date (Orig.) 2/10/2009

Model Year(s)/Program(s) N/A Key Date 2/10/2009 FMEA Date (Rev.) 6/2/2009

Core Team:

Process Action Results

Responsibility
Classification

Occurrence

Completion
Step Current Current

Detection

Occurrence
Severity
Potential Potential Potential

Detection
Target
Process Process Recommende

RPN

Severity
Date
Requirements Failure Effect(s) Causes(s) Actions Effective

RPN
Controls Controls d Action
Mode of Failure of Failure Taken Date
Prevention Detection
Function
10.c Identify Internal label Missing Moderate 4 Not enough labels 2 Lables printed Product 5 40 None
& inventory on each internal label production printed or lost labels for each lot scanned to
product container/box delays only inventory

Correct label Wrong label 4 Multiple product 2 None Visual 7 56 None

on each affixed received & labeled at inspection
container/box the same time

Product Wrong 4 Data entry error 2 TMM warning Inventory 5 40 None

inventory quantity for quantity levels reports;
updated w/ received discrepancies PO balance
new qty. reviews

10.d Inspect Material Wrong Loss of 8 Data entry error 2 TMM warning Visual 5 80 None
& release certification & material material for new lot evaluation &
product to sample with certification traceability, numbers TMM release
use each new lot entered may scrap or
(every lot for return 100%
outsourced of product
product)

Characteristic Product does Moderate 6 Nonconforming 3 Receiving log Dimensional & 5 90 None
s must match not conform disruption; product quality visual
specifications 100% of delivered by supplier inspection per
product may receiving log
have to be
reworked

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 CONTROL PLAN - RECEIVING
Prototype Pre-Launch ✘ Production Key Contact & Phone Date (orig.) Date (rev.)
Control Plan Number: Receiving 2/10/2009
Part Number Core Team Customer Engineering Approval /Date (If req'd)
All N/A
Part Name/ Description Organization/Plant Approval/Date Customer Quality Approval/Date (If req'd)
Raw materials & components N/A N/A
Organization/ Plant Organization Code Other Approval/ Date (If Req'd) Other Approval/Date (If req'd.)
0 N/A N/A
Characteristics Methods
Part / Process Name / Spec.
Machine, Device, Product/Process Evaluation
Process Operation Char. Sample Reaction Plan
Jig, Tools, For Mfg. No. Product Process Specification/ Measurement Control Method
Number Description Class
Tolerance Technique Size Freq.
10a Verify shipment & Lift truck Condition overall Product free of Visual Shipmen Each Unload shipment Refuse shipment & notify
unload damage t Purchasing

Completeness Shipment must Visual Shipmen Each TMM receiving Notify Purchasing of any
match bill of lading t updates discrepancies

10b Review & receive Computer system Identification Pallet labels and/or Visual Containe Each Product Identify product w/ Do
shipment TMM database part number on each r or box identification by Not Use tag, move to
container/box supplier Hold Area, then notify
Purchasing & QC
Certification Lot number on each Visual Containe Each Material
container or box r or box certification &
sample sent to QC
Product certification Visual Lot Each
for each new lot
(every lot for
outsourced product)

Product certification Visual Containe Each

must match product r or box
lot numbers
Quantity Label & packing list Visual Containe Each TMM receiving Notify Purchasing of any
quantities must r or box updates discrepancies
match
Verification An open order must Visual Lot Each Product received
exist for the product against open order
in TMM database
10c Identify & inventory Label printer Identification Internal label on Scanner Containe Each Product scanned Identify product w/ Do
product Barcode scanner each container/box r or box to receiving Not Use tag, move to
location Hold Area, then notify
Purchasing & QC
Correct label on Visual Containe Each
each container/box r or box

Inventory Product inventory Scanner & Visual Lot Each TMM inventory &
updated w/ new qty. receiving reports

10d Inspect & release Computer system Certification Material certification Visual Lot Each Product released Identify product w/ Do
product to use TMM database & sample with each in TMM database Not Use tag, move to
new lot (every lot for Hold Area, then notify
outsourced product) Purchasing & QC

395870692.xls Ctrl Plan Page 3 of 4

10d Inspect & release Computer system Identify product w/ Do
product to use TMM database Not Use tag, move to
Hold Area, then notify
Purchasing & QC

Characteristics must Receiving log

Characteristics Per receiving log Lot Each
match specifications updates

395870692.xls Ctrl Plan Page 4 of 4