POTENTIAL FAILURE MODES AND EFFECTS WORKSHEET
                     FMEA Type                                                                                     Level of Detail
                                   Design FMEA                           Process FMEA                                    System                Process                  Process Step Component / Part                                                                                                    FMEA Number --->                                    5637-2007
                                                                                                                                                                                                                                                                                                                                    Telephone #:                   Email address:
                     Product / Service                          345-474494-8475                                    Design or Process Responsibility                                    Alleak Valves                                            Prepared by --->                        Carl Spackler
                     Identifier --->                                                                               ------------->                                                                                                                                                                                                   585-555-1212                   test@info.com
                     End Product(s) / Model                RL-1500 Series Valves                                   Other relevant information --->        None                                                                                  Original Date --->                         May 29, 2007                             FMEA Revision Date                 October 2, 2007
                     Year(s) --->                                                                                                                                                                                                                                                                                                   ------>
                     Core Team --->             Eric Cartman (FMEA Owner), Kenny (Plant Mfg. rep.), Stan Marsh (engineering rep.), Kyle Brovlowski (quality rep.), Mr. Garrison (purchasing / supplier quality rep.), Mr. Hand (Internal Customer rep.), Chef (Customer rep.)
                                                                                                             S     T                                         Fishbone       O                                                                    D          R                                                                                                      S     O      D            R
                     Design Item or Process      Potential Failure Mode      Potential Effect(s) of Failure  e     y          Potential Cause(s) /            Cause         c     Current Process Controls -  Current Process Controls -         e          P             Recommended Actions            Responsibility & Target           Actions Taken            e     c     e             P
                     Function Requirements                                                                   v     p        Mechanism(s) of Failure          Category       c             Prevention                      Detection              t          N                                               Completion Date                                         v     c     t            N
                                                                                                                   e
                     saw cutting of tube        wrong length cut             regulatory violation             9     I wrong setup of saw                      method         3   setup programs                  1st piece verification           3         81
                                                                                                              9     I tube not fully held against             method         5   OJT                            sensor on back stop with          2         90
                                                                                                                         back stop                                                                              alarm
                                                                                                              9     I                                         method         0                                                                    0          0
                                                                                                                    I operator not trained properly            man               OJT process verifies           Training records
                                                                                                              9                                                              4   competence through                                               4        144
                                                                                                                                                                                 testing
                                                                                                              9     I operator tired or                        man           3   regular breaks / table         regular supervisor visits         5        135
                                                                                                                         uncomfortable                                           height can be adjusted
                                                                                                              9     I operator distracted                      man           4   5 S program                    regular supervisor visits         5        180
                                                                                                              9     I dull saw blade                         machine         3   PM checks every 1000           SPC checks every 2 hours          5        135
                                                                                                                                                                                 cuts
                                                                                                              9     I wrong saw RPM                          machine         3   setup programs                 1st piece verification            3         81
                                                                                                                    I backstop becomes loose                 machine             OJT                            SPC checks every 2 hours                               Improve clamp on backstop         Stan Marsh - 9/07          clamp improved and 
                                                                                                              9                                                              7                                                                    5        315         and add sensor to detect                                     sensor installed                9      3     2           54
                                                                                                                                                                                                                                                                       movement
                                                                                                              9     I tube straightness out of               material        2   Supplier approval Cpk of       CofA verified at incoming         7        126
                                                                                                                         specification                                           1.8                            inspection
                                                                                                                    I Tube hardness out of                   material            Supplier approval Cpk of .8 CofA verified at incoming                                 Initiate supplier corrective      Mr. Garrison - 9/07        CA completed and Cpk 
                                                                                                              9          specification                                       7                                  inspection                        7        441         action and development to                                    improved to 1.4                 9      3     7          189
                                                                                                                                                                                                                                                                       improve Cpk
                                                                                                                    I material expansion                     material            temperature controlled in      alarm system on 
                                                                                                              9                                                              4   manufacturing to 68 +/- 5      temperature gage /                2         72
                                                                                                                                                                                                                recorder
                                                                                                              9     I unorganized work area                environment       2   5S Program                     weekly 5S audits                  5         90
                                                                                                                    I excessive dirt, dust or metal        environment           OJT                            regular supervisor visits
                                                                                                              9          filings on saw cut table /                          5                                                                    5        225
                                                                                                                         back stop
                                                                                                                    I temperature out of                   environment           PM checks monthly -            alarm system on 
                                                                                                              9          specification                                       3   stability of gage              temperature gage /                2         54
                                                                                                                                                                                                                recorder
                                                                                                                    I backstop not setup properly -  measurement                 OJT                            1st piece verification
                                                                                                              9          measurement error                                   5                                                                    3        135
                                                                                                                    I gaging out of calibration           measurement            calibration frequency          SPC checks every 2 hours
                                                                                                                                                                                 appropriate and methods 
                                                                                                              9                                                              2   are capable - stability                                          5         90
                                                                                                                                                                                 studies 
                                                                                                                    I SPC checks not being done           measurement            OJT                            regular supervisor visits - 
                                                                                                                                                                                                                supervisor is required to 
                                                                                                              9                                                              5                                  verify SPC checks -               5        225
                                                                                                                                                                                                                sampling
                           Printed: 08/03/2022                                                                                                                                                                 Page 1 of 1                                                                                                                                    FMEA Template Revision: 29-May-07