RPN

(Risk
Severity Potential Occurre Current Detectio Responsi
Priority
(S) Causes nce (O) Controls n (D) bility
Number
)
8 low 4 Monitoring of 5 160 Maintena
pressure fuel pressure nce
fuel Team
injection
6 Low 5 High quality 6 180 Maintena
quality bearing nce
bearing Team
9 Improper 3 Low tolerance 4 108 Engine
size of piston ring Team
piston should be used
ring
10 Insufficie 2 Oil pressure 3 60 Engine
nt monitoring, Team
lubricatio quality
n bearings
9 Chain/ 3 Timing 4 108 Maintena
Belt inspections, nce
wear, adjuster Team
tension checks
issues
Exhaust Leak or Emissions 7 Exhaust 3 Visual 4 84 Exhaust High 7 2 2 28
Valve blockage issues, power valve inspections Team quality
loss spring valve
damage spring
Oil Pump low oil Engine wear, 10 2 Oil pressure 3 60 Maintena Improved 10 1 2 20
pressure overheating Pump moniotoring, nce pump
wear, regular Team design
blockage maintenance
Intake Bearing Power loss, 8 Insufficie 3 Regular oil 3 72 Engine Lubricati 8 2 2 32
pushrod failure excessive nt changes, Team on design
smoke lubricatio temperature updated
n monitoring
Intake Gasket Air leaks, 7 Gasket 4 Torque 4 112 Engine Proper 7 2 3 42
Manifold failure poor wear, checks, quality Team tolerance
performance improper gaskets gaskets
installatio use
n

DFMEA and Amended DFMEA

Design Failure Mode effects analysis (DFMEA) and amended DFMEA is the DFMEA after the
improvements and verification. The motto is to reduce the risk priority number (RPN) value by
taking action with rigorous testing and inspection. The details about the potential failure modes,
such as

1. Starting Problem: The problem comes under the component fuel injection, whose potential
effect was improper fuel delivery caused by low-pressure fuel injection, whose RPN was
calculated at 160. After the action taken with the diagnostic from the Electronic control unit, the
RPN decreased to 48.

2. Bearing Size: Bearing size comes under the component water pump, whose potential effect was
engine overheating caused by low-quality bearing, whose RPN was calculated to be 180. After
periodic inspection of the engine pressure, the RPN decreased to 72.

3. Wear or breakage of piston rings: Wear or breakage of piston rings which come under the
component piston rings whose potential effects was reduced engine compression and oil
consumption whose RPN calculated was 108 after periodic inspection of the engine pressure, the
RPN decreased to 54.

4. Main bearings wear: Main bearings wear under the component crankshaft, whose potential
effects were noises and vibration. The RPN was calculated to be 60 after high-quality bearing
materials, and the RPN decreased to 20.
5. Timing chain: The timing chain issue comes under the component camshaft, whose potential
effects were valve timing issues and engine damage, whose RPN calculated was 108. After the
improved design of the adjuster, the RPN decreased to 54.

6. Coolant leak: The coolant leak comes under the component camshaft, whose potential effects
were valve timing issues and engine damage. The RPN calculated 108 uses of high-quality hoses.
The RPN decreased to 54.

7. Leak or blockage: A leak or blockage issue comes under the component radiator, whose potential
effects were overheating and engine damage, whose RPN calculated was 180. Using a high-
quality valve spring, the RPN decreased to 54.

8. Low oil pressure: The low oil pressure issue comes under the component oil pump, whose
potential effects were engine wear overheating and whose RPN was calculated to be 60. With the
improved pump design, the RPN decreased to 20.

9. Bearing Failure: The bearing failure issue comes under the component intake pushrod, whose
potential effects were power loss and excessive smoke, whose RPN was calculated at 72. With
the action taken lubrication on design updated, the RPN decreased to 32.

10. Intake gasket failure: Intake gasket failure, which comes under the component intake manifold,
whose potential effects were air leaks and poor performance, whose RPN calculated was 12 with
the action proper tolerance gasket use, the RPN decreased to 42.