Ski rack
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Revision as of 17:21, 7 February 2011
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Ski Rack Bill of Materials
Ski Rack DFMA
Ski Rack FMEA
Ski Rack DFE
Contents |
Bill of Materials
Design for Manufacture and Assembly
Failure Mode and Effects Analysis
Ski Rack FMEA
Assembly | Function | Potential Mode of Failure | Potential Effect of Failure | Sev | Potential Cause of Failure | Occurance | Detection Controls | Detection | RPN |
---|---|---|---|---|---|---|---|---|---|
Bracket | Hold the rack onto the crossbars | Plastic Cracks | Rack Unstable | 5 | Cold | 2 | Material Choice | 1 | 10 |
Bracket | Hold the rack onto the crossbars | Plastic Cracks | Rack Unstable | 5 | Poor Manufacturing | 4 | N/A | 6 | 120 |
Bracket | Hold the rack onto the crossbars | Plastic Cracks | Rack Unstable | 5 | Vehicle Crash | 4 | N/A | 10 | 200 |
Bracket | Hold the rack onto the crossbars | Plastic Cracks | Rack Unstable | 5 | Overtorque | 4 | Allen Key Size | 7 | 140 |
Bracket | Hold the rack onto the crossbars | Bolt Shears | Rack Unstable | 5 | Vehicle Crash | 4 | N/A | 10 | 200 |
Bracket | Hold the rack onto the crossbars | Bolt Shears | Rack Unstable | 5 | Rust | 7 | Use Stainless Steel | 5 | 175 |
Bracket | Hold the rack onto the crossbars | Bolt Shears | Rack Unstable | 5 | User Bolt - Not Factory | 3 | Specific Shape and Thread | 10 | 150 |
Bracket | Hold the rack onto the crossbars | Bolt Shears | Rack Unstable | 5 | Overtorque | 4 | Allen Key Size | 7 | 140 |
Bracket | Hold the rack onto the crossbars | Bolt Shears | Rack Unstable | 5 | Undertorque | 3 | Allen Key Size | 7 | 105 |
Bracket | Hold the rack onto the crossbars | Mounting Grooves Wear | Rack Unstable | 5 | Vibrations | 3 | Material Choice | 5 | 75 |
Latch | Open and Close the Ski Rack on Request | Will Not Open | Cannot go skiing | 7 | Frozen | 5 | Material Choice | 8 | 280 |
Latch | Open and Close the Ski Rack on Request | Will Not Open | Cannot go skiing | 7 | Deformation | 6 | Material Choice | 8 | 280 |
Latch | Open and Close the Ski Rack on Request | Will Not Open | Cannot go skiing | 7 | Lost / Broken Key | 4 | Extra Key | 1 | 28 |
Latch | Open and Close the Ski Rack on Request | Will Not Open | Cannot go skiing | 7 | Broken Rivet | 2 | Material Thickness | 6 | 84 |
Latch | Open and Close the Ski Rack on Request | Will Not Close | Cannot go skiing | 7 | Broken Latch | 5 | Material Choice | 2 | 70 |
Latch | Open and Close the Ski Rack on Request | Will Not Close | Cannot go skiing | 7 | Deformation | 6 | Material Choice | 4 | 168 |
Latch | Open and Close the Ski Rack on Request | Will Not Close | Cannot go skiing | 7 | Lock Frozen Locked | 4 | Seal Lock to prevent moisture from entering | 4 | 112 |
Latch | Open and Close the Ski Rack on Request | Will Not Close | Cannot go skiing | 7 | Broken / Worn Spring | 3 | Spring Choice | 5 | 105 |
Latch | Open and Close the Ski Rack on Request | Will Not Close | Cannot go skiing | 7 | Broken Rivet | 2 | Material Choice | 6 | 84 |
Latch | Open and Close the Ski Rack on Request | Opens on its own | Loss of Skis, Potentially Fatal Accidents | 9 | Deformation | 6 | Material Choice | 4 | 216 |
Latch | Open and Close the Ski Rack on Request | Opens on its own | Loss of Skis, Potentially Fatal Accidents | 9 | Weakened Plastic | 7 | Material Choice | 6 | 378 |
Latch | Open and Close the Ski Rack on Request | Opens on its own | Loss of Skis, Potentially Fatal Accidents | 9 | Driving Forces Break Latch | 3 | Minimize Forces, Material Choice | 10 | 270 |
Latch | Open and Close the Ski Rack on Request | Opens on its own | Loss of Skis, Potentially Fatal Accidents | 9 | Ratchet Tooth Failure | 4 | Avoid Use of Ratchet Teeth | 8 | 288 |
Latch | Open and Close the Ski Rack on Request | Opens on its own | Loss of Skis, Potentially Fatal Accidents | 9 | Broken / Worn Spring | 3 | Spring Choice | 5 | 135 |
Latch | Open and Close the Ski Rack on Request | Opens on its own | Loss of Skis, Potentially Fatal Accidents | 9 | Broken Rivet | 2 | Material Thickness | 6 | 108 |
Latch | Open and Close the Ski Rack on Request | Not Fully Closed | Chance of Opening leading to loss of skis, potentially fatal accidents | 9 | Ratchet Tooth Barely Engaged | 6 | Color Notification | 2 | 108 |
Latch | Open and Close the Ski Rack on Request | Not Fully Closed | Chance of Opening leading to loss of skis, potentially fatal accidents | 9 | Debris in the Way | 8 | Color Notification | 2 | 144 |
Latch | Open and Close the Ski Rack on Request | Not Fully Closed | Chance of Opening leading to loss of skis, potentially fatal accidents | 9 | Too much in the rack | 6 | Color Notification | 2 | 144 |
Latch | Open and Close the Ski Rack on Request | User Forgets to Close | Loss of skis, potentially fatal accidents | 9 | Distracted User | 4 | Warning System | 6 | 216 |
Latch | Open and Close the Ski Rack on Request | User Forgets to Close | Loss of skis, potentially fatal accidents | 9 | Cannot See Open Rack | 2 | Visual Aide | 7 | 126 |
Crossbars | Holds the Skis Securely in Place | Does not hold the skis with sufficient force | Loss of skis, potentially fatal accidents | 9 | Different height of skis | 5 | Individually sliced rubber | 1 | 45 |
Crossbars | Holds the Skis Securely in Place | Does not hold the skis with sufficient force | Loss of skis, potentially fatal accidents | 9 | Bent Crossbars | 2 | Material Choice | 1 | 18 |
Crossbars | Holds the Skis Securely in Place | Does not hold the skis with sufficient force | Loss of skis, potentially fatal accidents | 9 | Unevenly worn rubber | 3 | Individually sliced rubber | 1 | 27 |
Crossbars | Holds the Skis Securely in Place | Holds the skis too tightly | Damage to skis | 6 | Too thick of a ski | 4 | More space between crossbars, taller rubber | 1 | 24 |
Crossbars | Holds the Skis Securely in Place | Holds the skis too tightly | Damage to skis | 6 | Bent Crossbars | 2 | Material Choice | 1 | 12 |
Crossbars | Holds the Skis Securely in Place | Holds the skis too tightly | Damage to skis | 6 | Rubber too hard | 3 | Material Choice | 3 | 54 |
Crossbars | Holds the Skis Securely in Place | Does not apply uniform pressure | Loss of skis, potentially fatal accidents | 9 | Different height of skis | 5 | Individually sliced rubber | 1 | 45 |
Crossbars | Holds the Skis Securely in Place | Does not apply uniform pressure | Loss of skis, potentially fatal accidents | 9 | Bent crossbars | 2 | Material | 1 | 18 |
Crossbars | Holds the Skis Securely in Place | Does not apply uniform pressure | Loss of skis, potentially fatal accidents | 9 | Unevenly worn rubber | 3 | Individually sliced rubber | 1 | 27 |
Crossbars | Holds the Skis Securely in Place | Does not keep skis from sliding | Loss of skis, potentially fatal accidents | 9 | Not enough friction | 1 | Material choice | 1 | 9 |
Crossbars | Holds the Skis Securely in Place | Does not keep skis from sliding | Loss of skis, potentially fatal accidents | 9 | Rubber too soft | 1 | Material choice | 3 | 27 |
Crossbars | Holds the Skis Securely in Place | Improperly loaded | Loss of skis, potentially fatal accidents, Damage to rack | 9 | Attempt to load over the binding | 4 | Less space between crossbars | 2 | 72 |
Crossbars | Holds the Skis Securely in Place | Improperly loaded | Loss of skis, potentially fatal accidents, Damage to rack | 9 | Attempt to load non-skis | 5 | Less space between crossbars | 4 | 180 |
Inside hinge | Align the crossbars as it closes | Does not align properly | Rack will not close | 7 | Crossbars bent | 2 | Material choice | 1 | 14 |
Inside hinge | Align the crossbars as it closes | Does not align properly | Rack will not close | 7 | Plastic | 6 | Material choice | 4 | 168 |
Inside hinge | Align the crossbars as it closes | Does not align properly | Rack will not close | 7 | Rivet broken | 2 | Material thickness | 6 | 84 |
Inside hinge | Align the crossbars as it closes | Does not fully open | Crossbars will not stay open | 3 | Customer cannot open it far enough | 4 | Create an easier way to open the rack | 2 | 24 |
Inside hinge | Align the crossbars as it closes | Does not fully open | Crossbars will not stay open | 3 | Plastic deformed | 6 | Material choice | 4 | 72 |
Inside hinge | Align the crossbars as it closes | Does not fully close | Cannot go skiing | 7 | Spring worn or broken | 3 | Spring choice | 5 | 105 |
Inside hinge | Align the crossbars as it closes | Does not fully close | Cannot go skiing | 7 | Plastic | 6 | Material | 4 | 168 |
Inside hinge | Align the crossbars as it closes | Does not hold the top and bottom crossbars together | Cannot go skiing | 7 | Rivet broken | 2 | Material thickness | 6 | 84 |
Inside hinge | Align the crossbars as it closes | Does not hold the top and bottom crossbars together | Cannot go skiing | 7 | Broken plastic | 4 | Material choice | 1 | 28 |
Riser | Increase clearance | Binding still does not clear roof | Vehicle gets scratched and dented | 3 | Not enough of a lift in design | 1 | Better design | 1 | 3 |
Riser | Increase clearance | Mount does not attach properly | Cannot go skiing | 7 | Rivet breaks | 2 | Material thickness | 6 | 84 |
Riser | Increase clearance | Mount does not attach properly | Cannot go skiing | 7 | Plastic breaks | 4 | Material choice | 1 | 28 |