DFMEA Sample For A Pen

POTENTIAL FAIL URE MODE AND EFFECTS ANAL YSIS (DESIGN FMEA) X System Subsystem Component Model Years(s)/Vehicle(s)
Core Team Chris Fox, Kerry Hinson 2008 XYZ Design Responsibility Dave Designer Key Date 6/27/2005 Page Prepared By FMEA Date (Orig.) Chris Fox 6/21/12 FMEA Number 05-XYZ
Action Results I t e m C L A S S
Part/ Part Number
Part Function
Failure Mode
Failure Effects
S E V
Causes/ Mechanisms of Failure
O C C
Current Design Controls
D E T
R P N
Recommended Actions
Responsibility & Target Completion Date
Actions Taken
S e v
O c c
D e t
R P N
Tool used for writing or drawing with a colored fluid, such as ink
Casing (Outer Tube)
Provides grip for writer
Casing designed too small
Won't fit in large hands comfortably, and could contribute to CTS.
Bad mating part (user's hand size) information
Print review system that includes evaluation of all mating parts, and possible clearance/interference issues by design team prior to release of print to toolmaker. Print review system that includes evaluation of all mating parts, and possible clearance/interference issues by design team prior to release of print to toolmaker.
48
Casing designed too large
Won't fit in small hands comfortably.
Bad mating part (user's hand size) information
48
Provides protection for mechanism and contents.
Ink reservoir will not actuate without binding.
Unable to move cartridge into point of operation without difficulty. Unable to move cartridge into point of operation
Internal cavity designed 2 too small
Tolerance stackup
48
Ink reservoir will not actuate, button mechanism pops off.
Internal cavity designed 2 too large
Tolerance stackup
48
Ink reservoir will not actuate, stylus larger than clearance hole.
Unable to move cartridge into point of operation
Hole designed too small. 2
Print review system that includes evaluation of all mating parts, and possible clearance/interference issues by design team prior to release of print to toolmaker.
48
Ink Reservoir
Stores ink until point of use.
Plastic material crossreacts with ink
Ink exhibits signs of contamination
Improper material selection.
Material Selection to reduce potential, and process controls
48
Leaks
Material failure - Cracks 6 or seepage.
Spray bar test, environmental testing.
48
Bent / Warped
FEA to determine material suitability
48
Ink reservoir will not actuate without binding.
Ink reservoir designed too large
Tolerance stackup
48
Cartridge profile incorrect
Bad mating part information
Tolerance stackup
48
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POTENTIAL FAIL URE MODE AND EFFECTS ANAL YSIS (DESIGN FMEA) X System Subsystem Component Model Years(s)/Vehicle(s) Core Team Chris Fox, Kerry Hinson 2008 XYZ Design Responsibility Dave Designer Key Date 6/27/2005 Page Prepared By FMEA Date (Orig.) Chris Fox 6/21/12 FMEA Number 05-XYZ
Part/ Part Number
Part Function
Failure Mode
Failure Effects
S E V
Causes/ Mechanisms of Failure
O C C
Current Design Controls
D E T
R P N
Recommended Actions
Actions Taken
S e v
O c c
D e t
R P N
Ink Stylus
Act as a cap to keep the ink from drying
Accidentally dry in the pen
Ink gums the whole thing 6 up and requires meticulous cleaning
Designed overclearance 2
Acts as a buffer between the material and the quick-drying ink inside the pen
48
Lets ink flow out of the pen at a Flow unevenly controlled rate
Flow unevenly
Designed overclearance 2
Small rotating ball made of brass, steel or tungsten carbide to disperse ink
48
Clogged / Bound ballpoint
Flow unevenly
Clogged / Bound ballpoint
Reliability testing
48
Ballpoint Oversized
Flow unevenly
Ballpoint Oversized
Pre-production validation
48
Ballpoint Undersized
Flow unevenly
Ballpoint Undersized
Pre-production validation
48
Contamination / Corrosion
Flow unevenly
Reliability testing
48
Bent / Warped
Flow unevenly
Bent / Warped
Material Selection to reduce potential, and process controls
48
Ink
Viscosity too thin
Wrong ingredient(s) for application
Materials Testing
48
Viscosity too thick
Materials Testing
48
Ingredient: Vehicle
Acts as fluid to transport pigmentsand coloring
Wrong formulation for writing substrate
Slow to dry
Pre-production validation, reliability testing
48
Ingredient: Coloring
Makes writing darker and clearer.
Color Missing
48
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POTENTIAL FAIL URE MODE AND EFFECTS ANAL YSIS (DESIGN FMEA) X System Subsystem Component Model Years(s)/Vehicle(s) Core Team Chris Fox, Kerry Hinson 2008 XYZ Design Responsibility Dave Designer Key Date 6/27/2005 Page Prepared By FMEA Date (Orig.) Chris Fox 6/21/12 FMEA Number 05-XYZ
Part/ Part Number
Part Function
Failure Mode Color Wrong
Failure Effects
S E V 6
O Causes/ Mechanisms C of Failure Current Design Controls C Wrong ingredient(s) for 2 Pre-production validation, reliability testing application
D R E P T N 4 48
Recommended Actions
Actions Taken
S e v
O c c
D e t
R P N
Ingredient: Additive
Stabilize and provide additional desirable characteristics.
48
Button Mechanism
Protects user and contents when not in use
Button stays in down position.
Ink leaks when not in use.
Spring failure / defective 2
48
Cam failure / defective
48
Reliability testing
48
Page 3 of 3

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POTENTIAL FAIL URE MODE AND EFFECTS ANAL YSIS (DESIGN FMEA) X System Subsystem Component Model Years(s)/Vehicle(s)

Part/ Part Number

Causes/ Mechanisms of Failure

Current Design Controls

Responsibility & Target Completion Date

Casing (Outer Tube)

Provides grip for writer

Casing designed too small

Won't fit in large hands comfortably, and could contribute to CTS.

Bad mating part (user's hand size) information

Casing designed too large

Won't fit in small hands comfortably.

Bad mating part (user's hand size) information

Provides protection for mechanism and contents.

Ink reservoir will not actuate without binding.

Internal cavity designed 2 too small

Ink reservoir will not actuate, button mechanism pops off.

Internal cavity designed 2 too large

Unable to move cartridge into point of operation

Hole designed too small. 2

Stores ink until point of use.

Plastic material crossreacts with ink

Ink exhibits signs of contamination

Improper material selection.

Material Selection to reduce potential, and process controls

Material failure - Cracks 6 or seepage.

Improper material selection.

Spray bar test, environmental testing.

Unable to move cartridge into point of operation

Improper material selection.

FEA to determine material suitability

Ink reservoir will not actuate without binding.

Unable to move cartridge into point of operation

Ink reservoir designed too large

Cartridge profile incorrect

Unable to move cartridge into point of operation

Bad mating part information

Part/ Part Number

Causes/ Mechanisms of Failure

Current Design Controls

Responsibility & Target Completion Date

Act as a cap to keep the ink from drying

Accidentally dry in the pen

Ink gums the whole thing 6 up and requires meticulous cleaning

Clogged / Bound ballpoint

Clogged / Bound ballpoint

Material Selection to reduce potential, and process controls

Viscosity too thin

Wrong ingredient(s) for application

Viscosity too thick

Wrong ingredient(s) for application

Acts as fluid to transport pigmentsand coloring

Wrong formulation for writing substrate

Wrong ingredient(s) for application

Pre-production validation, reliability testing

Makes writing darker and clearer.

Wrong ingredient(s) for application

Pre-production validation, reliability testing

Part/ Part Number

Failure Mode Color Wrong

Responsibility & Target Completion Date

Stabilize and provide additional desirable characteristics.

Wrong ingredient(s) for application