FMEA
Which step can hurt Hartwell, and how would we notice?
| Process | Failure mode | Effect | S | O | D | RPN | Current control |
|---|---|---|---|---|---|---|---|
| Inspect the seat | Inspect skipped on an expedite | The seat ships without the bench check. | 8 | 4 | 7 | 224 | Ra sample of 1 of 5. Stop and call Priya Shah over 32 µin. |
| Confirm the shipment | Docknote and Ledgerline disagree | The confirm can be posted on the wrong day. | 7 | 6 | 5 | 210 | Docknote and Ledgerline agree before Helen Ward writes to Ruth Adeyemi. |
| Machine the seat face | Traveler still showing Rev B | Leak at Hartwell. | 9 | 6 | 3 | 162 | Mara Ellison does not release a mismatch. Devon Cho stops the setup. |
| Kit and pack | Seal missing at pack | The packing count does not match the list. | 6 | 5 | 4 | 120 | Packing count against the list at the pack bench. |
How this sheet sits with the others
A traveler still showing Rev B can leak at Hartwell. The current control is that Mara does not release a mismatch and Devon stops the setup. The plant marks severity, occurrence, and detection as 9, 6, and 3. An inspect skipped on an expedite is marked 8, 4, and 7. A seal missing at pack is marked 6, 5, and 4. Docknote and Ledgerline disagreeing is marked 7, 6, and 5. The marks are the plant’s current judgment, kept modest. The sheet has no frequency chart and does not test a cause.
- What it makes visible
- Four failure modes, the plant’s current 1–10 marks, and the current control in words.
- When it is useful
- When the team needs to say how a miss reaches Hartwell before it tests a cause.
- Who uses it
- Devon Cho, Priya Shah, Luis Ortega, and Helen Ward, on the modes that reach Ruth Adeyemi’s crew.
- What it takes
- The modes the path already knows, and modest severity, occurrence, and detection marks.
- What it leaves
- Traveler Rev B at 9, 6, and 3. Skipped inspect at 8, 4, and 7. Missing seal at 6, 5, and 4. Docknote and Ledgerline disagreeing at 7, 6, and 5. Each row names its current control.
- The underlying record
- A traveler still on Rev B, an inspect skipped for an expedite, a seal missing at Luis Ortega's pack bench, and Docknote disagreeing with Ledgerline are the harms the map, the control plan, and the A3 are written around.
Where these facts go next
What this sheet still leaves out
It has no frequency chart and no test of cause.