Customer Complaints and Visual Inspections - Process FMEAs

D

dbulak

#1
Does a customer complaint have to be evaluated as at least a 7 for severity? Also, if we use visual inspection, does it have to have at least a number 8 assigned to it? I am new at PFMEA's and this is what our customer is telling these numbers have to be assigned. Is he correct?
 
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bobdoering

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#2
Does a customer complaint have to be evaluated as at least a 7 for severity? Also, if we use visual inspection, does it have to have at least a number 8 assigned to it? I am new at PFMEA's and this is what our customer is telling these numbers have to be assigned. Is he correct?
It is not so much a customer complaint as it is what caused the customer to complain. A severity of 7 is considered "Degradation of primary function OR a portion of the production run may have to be scrapped. Deviation from primary process including decreased line speed or added manpower" (AIAG FMEA 4th ed.) Not sure if that is applicable or not - but it is not easy to argue with the customer on ratings. They write the checks.

For visual, yes, AIAG criteria calls detection an 8 if inspected after it leaves the station where the characteristic is made (a 7 if in-station - see page 100 of AIAG FMEA 4th ed.). The high rating is primarily because it is considered terribly unreliable compared to the other detection schema (in-station automatic detection or foolproof prevention)
 

Jim Wynne

Staff member
Admin
#3
Does a customer complaint have to be evaluated as at least a 7 for severity?
No, unless that rating is specifically required by a customer.

Also, if we use visual inspection, does it have to have at least a number 8 assigned to it? I am new at PFMEA's and this is what our customer is telling these numbers have to be assigned. Is he correct?
The customer is correct if that's what they want you to do, even though it might not make sense in all applications. Do you have a copy of the AIAG FMEA manual? Are you required to used the rating guidelines from the manual?
 
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