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| Item | FMEA Claim | Physical Check | Finding | Action | | :--- | :--- | :--- | :--- | :--- | | Bracket orientation | Poka-yoke pin prevents reversal | Pin is present but operator removes it to speed up | Detection (D) should be 8, not 3 | Redesign pin to be non-removable | | Grease application | Automatic dispenser, 2g ±0.1g | Manual backup used 50% of time; average 1.2g | New failure mode: "Under-lubrication" | Disable manual override, add weight sensor | | Barcode scan | Scanner reads 100% of labels | 5% of labels smudged – operator manually keys number | Occurrence (O) = 4 (not 2) | Change label material | reverse fmea pdf
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