A Design Potential FMEA is an analytical technique used by a cross-functional team to ensure that all potential failure modes and their associated causes have been identified and actioned. Complete assemblies, along with every related system, subassembly and component should be evaluated.
The Design Potential FMEA does not rely on process controls to overcome potential design weaknesses, but it does take the technical / physical limits of the manufacturing / assembly process into consideration, for example:
Necessary mould drafts
Limited surface finish
Assembling space / access for tooling
Limited hardenability of steels
Tolerance / process capability / performance
The Design Potential FMEA can also take into consideration the technical / physical limits of product maintenance (service) and recycling, for example:
Tool access
Diagnostic capability
Material classification symbols (for recycling)
When developing countermeasure actions for potential failure modes, the supplier shall ensure that the feasibility of each countermeasure from a manufacturing perspective is analysed before implementing the action.
Minimum Content Requirement
Follow the guidelines described in the AIAG Potential Failure Mode and Effects Analysis manual (latest edition) and ensure that the Nissan specific requirements listed below are also included.
Item
Kasai UK Additional Requirement
Item
This should include all assemblies, sub-assemblies and components down to basic component part level (e.g. bolt, gasket, etc.)
Function
Describe as accurately as possible the function of each item.
Where the item has multiple functions, each function shall be evaluated separately without omission.
Potential Failure Mode
Anticipate and describe all possible ways the part could fail, not how it will fail.
When describing the failure mode, avoid using non-specific terms such as ‘damage’ etc.
Potential Effect(s) of Failure
The supplier must contact Nissan in order to fully understand the functional relationship between the item being analysed and other assembly parts/ systems. The effect(s) of the failure on these functional relationship must be considered.
Potential Cause(s)/ Mechanism(s) of Failure
List every potential cause and/or failure mechanism for each failure mode.
Recommended Actions
Study and describe the Recommended Actions from the point of view of Design revision / Design Validation / Design Verification according to the result of Risk Priority Number assessment.
Recommended Actions such as, but not limited to, the following should be considered:
-Revised design geometry and / or Tolerances,
-Revised material specification,
-Design of experiments,
-Revised test plan (Design Verification and Product / Process Validation)
The supplier should use the 5W1H (What, Where, When, Why, Who and How) analysis technique to help fully describe every potential failure mode or cause/ mechanism of failure.
The supplier must ensure consistency throughout all documentation (e.g.: Control plan, Process Flow Chart , Special Characteristic and Key Features Diagram, Inspection Report, FMEA) for:
- operation step numbering
- product characteristics identification
Document Description
Item
Completion Instructions
Project
Kasai UK Vehicle project for which the product is being developed / manufactured.
Kasai UK Important Part
Tick all boxes that apply to the product being developed / manufactured.
Document Reference No./ Version
The Suppliers reference no. and version no. for the document.
Document Revision Date
The date of the latest revision of the document.
Document Origin Date
The date when the document was first issued.
Supplier Name
Supplier Company name.
Supplier Plant
Location at which the product will be produced.
Supplier Code
Unique code to each supplier, issued by Kasai UK Purchasing Dept.
Author
The name of the person who created / revised the document
E-mail
The E-mail address of the person who created / revised the document.
Tel
The telephone number of the person who created / revised the document
Part Name
The part name or description as identified on the product drawing
Part No. & Issue Level:
As issued by Kasai UK design department
Design Note No.
The latest design note number that applies to the product being developed / manufactured
For rules related to document submission, refer to the Submission Rules page.
