Design Failure Mode and Effects Analysis (DFMEA)

FMEA Name 2021 Rivian R1 FMEA #: FMEA Status: Open

Responsible Engineer: Abdul Baseer and Rob Ratekin Prepared by: K. Martin Complete Date:

Current Design
Current Design
Controls Action Item
Controls

New OCC

New RPN
New SEV

New DET
S O D R
Line No.

Potential Cause(s) (Design actions planned or Recommended Target

Marker
Class
Requirement / Specification Potential Failure Mode Potential Effect(s) (Analytical or physical Actions Taken Status
E / Mechanism(s) completed to prevent or reduce C E P Action(s) Responsibility Completion
Part / Interface Function (reference) (Loss of Function) of Failure occurrence of failure, provide details
validation method planned or (status description) (Open ,
V of Failure C T N (not already planned) Date
completed) Closed)
and Best Practices used)
Detection
Prevention

Torn lip causing contact

(wind, water, dust
intrusion)(5)
FEA confirmed reduced stress
Provide Pleasing Appearance that is unappealing to Visable streaks on door (4) 1. Knit line failure resulting in torn lip, poor
164 Aero Seal See DTS and Finish Specifications 5 P01 level with new knit line design 3 Additional slam tests 3 45 Not at this time.
Appearance customer Part shows wear through appearance, loss of function
change
(4)
Seal is gapping to sheet
metal (4)

Torn lip causing contact

(wind, water, dust
intrusion)(5) Design layout studies with door - Prototype builds
Provide Pleasing Appearance that is unappealing to Visable streaks on door (4) 2. Excessive contact of lip to fender due to swing, Typical sections review, - Pressure Mapping
165 Aero Seal See DTS and Finish Specifications 5 P01 2 2 20 Not at this time.
Appearance customer Part shows wear through tight seal gap, Design criteria, Interface control - Mockups
(4) documents - Design studies
Seal is gapping to sheet
metal (4)
Torn lip causing contact
(wind, water, dust - Previous part history
intrusion)(5) - Design criteria - Prototype builds
Provide Pleasing Appearance that is unappealing to Visable streaks on door (4) 4. Uncoordinated dimensions between pins -Interface control documents - Mockups
167 Aero Seal See DTS and Finish Specifications 5 P01 2 2 20 Not at this time.
Appearance customer Part shows wear through on seals on hole in doors -SP Best Practice - Design studies
(4) - Design studies - Rapid prototypes
Seal is gapping to sheet
metal (4)

- Previous part history

- Design criteria
Part causes ergonomic -Interface control documents - Prototype builds
168 Aero Seal Design for Service hand clearance, tool clearance and ergo Part is difficult to service 5 1. Incorrect pins in part 2 2 20 Not at thsii time
issues for operator to install -SP Best Practice - DVP&R
- Design studies

- Previous part history

- Design criteria - Prototype builds
Part causes ergonomic 2. Uncoordinated dimensions between pins -Interface control documents - Mockups
169 Aero Seal Design for Service hand clearance, tool clearance and ergo Part is difficult to service 5 P01 2 2 20 Not at this time.
issues for operator to install on seals on hole in doors -SP Best Practice - Design verification on
- Design studies door.

- Previous part history

- Design criteria
Prevent / Manage Water Entry to Interior, Part allows dust Intrusion, -Interface control documents - Prototype builds
Aero Seal to Hood Inner
170 Sealing manage dust, CO, and contaminant Does not seal Wind Noise, or excessive 5 P01 1. Improper material selected for seal -SP Best Practice 2 - Mockups 3 30 Not att his time
Sheet Metal
intrusion. Road Noise - Design studies - DVP&R
-SAE Callout

- FEA - Prototype builds

Prevent / Manage Water Entry to Interior, Part allows dust Intrusion, - Lessons learned - DVP&R
Aero Seal to Hood Inner
171 Sealing manage dust, CO, and contaminant Does not seal Wind Noise, or excessive 5 P01 2. Incorrect seal base shape designed. - Design Review 2 - Design Studies 2 20 Not at this itme
Sheet Metal
intrusion. Road Noise -- Benchmarking - Rapid prototypes
- Mockups

- Benchmarking - Prototype builds

Prevent / Manage Water Entry to Interior, Part allows dust Intrusion,
Aero Seal to Hood Inner 3. Incorrect push pin locations specified (pin - Design Study/Review - Rapid prototypes Verify at Beta with different hole
172 Sealing manage dust, CO, and contaminant Does not seal Wind Noise, or excessive 5 P01 2 5 50 SUP Steve Haar 1-Dec-19
Sheet Metal spacing) - FEA - Mockups locations in seals
intrusion. Road Noise
- SP Best Practice

- Prototype builds
- Benchmarking
Part allows dust Intrusion, - DVP&R
Aero Seal to Hood Inner Does not adequately prevent the - Design Study/Review
173 Minimize Air flow to Interior < 8 / 15 CFM per door based on VTS req Wind Noise, or excessive 5 P01 1. Improper material selected for seal 2 - Design Studies 2 20 Not at this time.
Sheet Metal intrusion of air into the cabin - FEA
Road Noise - Rapid prototypes
- SP Best Practice
- Mockups

- Prototype builds
- Benchmarking
Part allows dust Intrusion, - DVP&R
Aero Seal to Hood Inner Does not adequately prevent the - Design Study/Review
174 Minimize Air flow to Interior < 8 / 15 CFM per door based on VTS req Wind Noise, or excessive 5 P01 2. Incorrect seal base shape designed. 2 - Design Studies 2 20 Not at this time.
Sheet Metal intrusion of air into the cabin - FEA
Road Noise - Rapid prototypes
- SP Best Practice
- Mockups

- Benchmarking - Prototype builds

Part allows dust Intrusion,
Aero Seal to Hood Inner Does not adequately prevent the 3. Incorrect push pin locations specified (pin - Design Study/Review - Rapid prototypes Verify at Beta with different hole
175 Minimize Air flow to Interior < 8 / 15 CFM per door based on VTS req Wind Noise, or excessive 5 P01 2 5 50 SUP Steve Haar 1-Dec-19
Sheet Metal intrusion of air into the cabin spacing) - FEA - Mockups locations in seals
Road Noise
- SP Best Practice

-Benchmarking
- Prototype builds
- FEA study
VTS Performance based dB Increment. - DVP&R
Aero Seal to Hood Inner - Previous part history
176 Minimizing Noise Minimize road noise, wind noise and squeak Does not minimize NVH Squeak/itch noise 5 P01 1. Improper material selected for seal 2 - Design Studies 2 20 Not at thisa time
Sheet Metal - SAE callout
and rattle. - Rapid prototypes
- long term material studies
- Mockups
- SOR.

-Benchmarking
- Prototype builds
- FEA study
VTS Performance based dB Increment. - DVP&R
Aero Seal to Hood Inner - Previous part history
177 Minimizing Noise Minimize road noise, wind noise and squeak Does not minimize NVH Squeak/itch noise 5 P01 2. Incorrect seal base shape designed. 2 - Design Studies 2 20 Not at this time.
Sheet Metal - SAE callout
and rattle. - Rapid prototypes
- long term material studies
- Mockups
- SOR.

- Benchmarking - Prototype builds

VTS Performance based dB Increment. - Design Study/Review - DVP&R
Aero Seal to Hood Inner 3. Incorrect push pin locations specified (pin Verify at Beta with different hole
178 Minimizing Noise Minimize road noise, wind noise and squeak Does not minimize NVH Squeak/itch noise 5 P01 - FEA 2 - Design Studies 5 50 SUP Steve Haar 1-Dec-19
Sheet Metal spacing) locations in seals
and rattle. - SP Best Practice - Rapid prototypes
- Mockups

Ensure hand and / or tool clearance

Meet ergonomic requirements
Ensure ease of assembly and able to - Benchmarking
- Prototype builds
assemble - Design Study/Review
Aero Seal to Hood Inner Part causes ergonomic 1. Uncoordinated dimensions between pins - Mockups
179 Design for Assembly Ensure correct part orientation and correct Part is difficult to install 5 P01 - FEA 2 2 20 Not at this time.
Sheet Metal issues for operator to install on seals on hole in doors - Design verification on
part can be assembled - SP Best Practice
door.
Ensure no damage during assembly
Ensure part cannot be mis-assembled or
partially assembled.

Page 1 of 4
Printed: 7/21/2022 GM Confidential Rivan Hood Seals DFMEA 18FEB2021
 Design Failure Mode and Effects Analysis (DFMEA)
FMEA Name 2021 Rivian R1 FMEA #: FMEA Status: Open
Responsible Engineer: Abdul Baseer and Rob Ratekin Prepared by: K. Martin Complete Date:

Current Design
Current Design
Controls Action Item
Controls

New OCC

New RPN
New SEV

New DET
S O D R
Line No.

Potential Cause(s) (Design actions planned or Recommended Target

Marker
Class
Requirement / Specification Potential Failure Mode Potential Effect(s) (Analytical or physical Actions Taken Status
E / Mechanism(s) completed to prevent or reduce C E P Action(s) Responsibility Completion
Part / Interface Function (reference) (Loss of Function) of Failure occurrence of failure, provide details
validation method planned or (status description) (Open ,
V of Failure C T N (not already planned) Date
completed) Closed)
and Best Practices used)
Detection
Prevention

Ensure hand and / or tool clearance

Meet ergonomic requirements
Ensure ease of assembly and able to - Benchmarking
assemble - Design Study/Review
Aero Seal to Hood Inner Part causes ergonomic - Prototype builds
180 Design for Assembly Ensure correct part orientation and correct Part is difficult to install 5 2. Incorrect pins in part - FEA 2 5 50 Not at this time.
Sheet Metal issues for operator to install - DVP&R
part can be assembled - SP Best Practice
Ensure no damage during assembly
Ensure part cannot be mis-assembled or
partially assembled.

- Benchmarking
- Prototype builds
Prevent / Manage Water Entry to Interior, Part allows dust Intrusion, 2. Inconsistent seal compression due to - Design Study/Review
- Pressure Mapping
182 Aero Seal to Fender Trim Sealing manage dust, CO, and contaminant Does not seal Wind Noise, or excessive 5 P01 varying sealing gap (not including seal gap - FEA 2 2 20 Not at this time.
- Mockups
intrusion. Road Noise change) - SP Best Practice
- Design studies

- Benchmarking
- Prototype builds
Prevent / Manage Water Entry to Interior, Part allows dust Intrusion, - Design Study/Review
- Pressure Mapping
183 Aero Seal to Fender Trim Sealing manage dust, CO, and contaminant Does not seal Wind Noise, or excessive 5 P01 3. Inadequate sealing surface - FEA 6 2 60 Not at this time.
- Mockups
intrusion. Road Noise - SP Best Practice
- Design studies

- Benchmarking
- Prototype builds
Prevent / Manage Water Entry to Interior, Part allows dust Intrusion, - Design Study/Review
- Pressure Mapping
184 Aero Seal to Fender Trim Sealing manage dust, CO, and contaminant Does not seal Wind Noise, or excessive 5 4. Improper lip design - FEA 2 2 20 Not at this time.
- Mockups
intrusion. Road Noise - SP Best Practice
- Design studies

- Benchmarking
- Prototype builds
Prevent / Manage Water Entry to Interior, Part allows dust Intrusion, - Design Study/Review
5. Inadequate design geometry of the lip, - Pressure Mapping
185 Aero Seal to Fender Trim Sealing manage dust, CO, and contaminant Does not seal Wind Noise, or excessive 5 - FEA 2 2 20 Not a tthis time
Shape/wall thickness. - Mockups
intrusion. Road Noise - SP Best Practice
- Design studies

- Benchmarking
- Prototype builds
Part allows dust Intrusion, 2. Inconsistent seal compression due to - Design Study/Review
Does not adequately prevent the - Pressure Mapping
187 Aero Seal to Fender Trim Minimize Air flow to Interior < 8 / 15 CFM per door based on VTS req Wind Noise, or excessive 5 P01 varying sealing gap (not including seal gap - FEA 2 2 20 Not at this time.
intrusion of air into the cabin - Mockups
Road Noise change) - SP Best Practice
- Design studies

- Benchmarking
- Prototype builds
Part allows dust Intrusion, - Design Study/Review
Does not adequately prevent the - Pressure Mapping
188 Aero Seal to Fender Trim Minimize Air flow to Interior < 8 / 15 CFM per door based on VTS req Wind Noise, or excessive 5 3. Inadequate sealing surface - FEA 6 2 60 Not at this time.
intrusion of air into the cabin - Mockups
Road Noise - SP Best Practice
- Design studies

- Benchmarking
- Prototype builds
Part allows dust Intrusion, - Design Study/Review
Does not adequately prevent the - Pressure Mapping
189 Aero Seal to Fender Trim Minimize Air flow to Interior < 8 / 15 CFM per door based on VTS req Wind Noise, or excessive 5 P01 4. Improper lip design (swing clearance) - FEA 2 2 20 Not this time
intrusion of air into the cabin - Mockups
Road Noise - SP Best Practice
- Design studies

- Benchmarking
- Prototype builds
Part allows dust Intrusion, - Design Study/Review
Does not adequately prevent the 5. Inadequate design geometry of the lip, - Pressure Mapping
190 Aero Seal to Fender Trim Minimize Air flow to Interior < 8 / 15 CFM per door based on VTS req Wind Noise, or excessive 5 - FEA 2 2 20 Not at this time.
intrusion of air into the cabin Shape/wall thickness. - Mockups
Road Noise - SP Best Practice
- Design studies

- Benchmarking
- Prototype builds
VTS Performance based dB Increment. 2. Inconsistent seal compression due to - Design Study/Review
- Pressure Mapping
192 Aero Seal to Fender Trim Minimizing Noise Minimize road noise, wind noise and squeak Does not minimize NVH Squeak/itch noise 5 P01 varying sealing gap (not including seal gap - FEA 2 2 20 Not at this time.
- Mockups
and rattle. change) - SP Best Practice
- Design studies

- Benchmarking
- Prototype builds
VTS Performance based dB Increment. - Design Study/Review
- Pressure Mapping
193 Aero Seal to Fender Trim Minimizing Noise Minimize road noise, wind noise and squeak Does not minimize NVH Squeak/itch noise 5 P01 3. Improper lip design (swing clearance) - FEA 2 2 20 Not at this time.
- Mockups
and rattle. - SP Best Practice
- Design studies

- Benchmarking
- Prototype builds
VTS Performance based dB Increment. - Design Study/Review
4. Inadequate design geometry of the lip, - Pressure Mapping
194 Aero Seal to Fender Trim Minimizing Noise Minimize road noise, wind noise and squeak Does not minimize NVH Squeak/itch noise 5 - FEA 2 2 20 Not at this time.
Shape/wall thickness. - Mockups
and rattle. - SP Best Practice
- Design studies

- Benchmarking
- Prototype builds
- Design Study/Review
1. Improper design geometry of the seal lip. - Pressure Mapping
195 Aero Seal to Fender Trim Enable Low Closing Efforts < 3.0 Joules total system Door is difficult to close High closing efforts 5 - FEA 2 2 20 Not at this time.
Shape/ thickness. - Mockups
- SP Best Practice
- Design studies

- Benchmarking
- Prototype builds
2. Inconsistent seal compression due to - Design Study/Review
- Pressure Mapping
196 Aero Seal to Fender Trim Enable Low Closing Efforts < 3.0 Joules total system Door is difficult to close High closing efforts 5 P01 varying sealing gap (not including seal gap - FEA 2 2 20 Not at this time.
- Mockups
change) - SP Best Practice
- Design studies

- Benchmarking
- Design Study/Review - Prototype builds
3. Seal section design not robust to build
197 Aero Seal to Fender Trim Enable Low Closing Efforts < 3.0 Joules total system Door is difficult to close High closing efforts 5 - FEA 4 - abrasion resistance 2 40 Not at this time.
variation
- SP Best Practice testing

Torn lip causing contact

(wind, water, dust
intrusion)(5)
FEA confirmed reduced stress
Provide Pleasing Appearance that is unappealing to Visable streaks on door (4) 1. Knit line failure resulting in torn lip, poor
164 Dust Seal See DTS and Finish Specifications 5 P01 level with new knit line design 3 Additional slam tests 3 45 Not at this time.
Appearance customer Part shows wear through appearance, loss of function
change
(4)
Seal is gapping to sheet
metal (4)

Torn lip causing contact

(wind, water, dust
intrusion)(5) Design layout studies with door - Prototype builds
Provide Pleasing Appearance that is unappealing to Visable streaks on door (4) 2. Excessive contact of lip to fender due to swing, Typical sections review, - Pressure Mapping
165 Dust Seal See DTS and Finish Specifications 5 P01 2 2 20 Not at this time.
Appearance customer Part shows wear through tight seal gap, Design criteria, Interface control - Mockups
(4) documents - Design studies
Seal is gapping to sheet
metal (4)

Page 2 of 4
Printed: 7/21/2022 GM Confidential Rivan Hood Seals DFMEA 18FEB2021
 Design Failure Mode and Effects Analysis (DFMEA)
FMEA Name 2021 Rivian R1 FMEA #: FMEA Status: Open
Responsible Engineer: Abdul Baseer and Rob Ratekin Prepared by: K. Martin Complete Date:

Current Design
Current Design
Controls Action Item
Controls

New OCC

New RPN
New SEV

New DET
S O D R
Line No.

Potential Cause(s) (Design actions planned or Recommended Target

Marker
Class
Requirement / Specification Potential Failure Mode Potential Effect(s) (Analytical or physical Actions Taken Status
E / Mechanism(s) completed to prevent or reduce C E P Action(s) Responsibility Completion
Part / Interface Function (reference) (Loss of Function) of Failure occurrence of failure, provide details
validation method planned or (status description) (Open ,
V of Failure C T N (not already planned) Date
completed) Closed)
and Best Practices used)
Detection
Prevention

Torn lip causing contact

(wind, water, dust - Previous part history
intrusion)(5) - Design criteria - Prototype builds
Provide Pleasing Appearance that is unappealing to Visable streaks on door (4) 4. Uncoordinated dimensions between pins -Interface control documents - Mockups
167 Dust Seal See DTS and Finish Specifications 5 P01 2 2 20 Not at this time.
Appearance customer Part shows wear through on seals on hole in doors -SP Best Practice - Design studies
(4) - Design studies - Rapid prototypes
Seal is gapping to sheet
metal (4)

- Previous part history

- Design criteria
Part causes ergonomic -Interface control documents - Prototype builds
168 Dust Seal Design for Service hand clearance, tool clearance and ergo Part is difficult to service 5 1. Incorrect pins in part 2 2 20 Not at thsii time
issues for operator to install -SP Best Practice - DVP&R
- Design studies

- Previous part history

- Design criteria - Prototype builds
Part causes ergonomic 2. Uncoordinated dimensions between pins -Interface control documents - Mockups
169 Dust Seal Design for Service hand clearance, tool clearance and ergo Part is difficult to service 5 P01 2 2 20 Not at this time.
issues for operator to install on seals on hole in doors -SP Best Practice - Design verification on
- Design studies door.

- Previous part history

- Design criteria
Prevent / Manage Water Entry to Interior, Part allows dust Intrusion, -Interface control documents - Prototype builds
Dust Seal to Hood Inner
170 Sealing manage dust, CO, and contaminant Does not seal Wind Noise, or excessive 5 P01 1. Improper material selected for seal -SP Best Practice 2 - Mockups 3 30 Not att his time
Sheet Metal
intrusion. Road Noise - Design studies - DVP&R
-SAE Callout

- FEA - Prototype builds

Prevent / Manage Water Entry to Interior, Part allows dust Intrusion, - Lessons learned - DVP&R
Dust Seal to Hood Inner
171 Sealing manage dust, CO, and contaminant Does not seal Wind Noise, or excessive 5 P01 2. Incorrect seal base shape designed. - Design Review 2 - Design Studies 2 20 Not at this itme
Sheet Metal
intrusion. Road Noise -- Benchmarking - Rapid prototypes
- Mockups

- Benchmarking - Prototype builds

Prevent / Manage Water Entry to Interior, Part allows dust Intrusion,
Dust Seal to Hood Inner 3. Incorrect push pin locations specified (pin - Design Study/Review - Rapid prototypes Verify at Beta with different hole
172 Sealing manage dust, CO, and contaminant Does not seal Wind Noise, or excessive 5 P01 2 5 50 SUP Steve Haar 1-Dec-19
Sheet Metal spacing) - FEA - Mockups locations in seals
intrusion. Road Noise
- SP Best Practice

- Prototype builds
- Benchmarking
Part allows dust Intrusion, - DVP&R
Dust Seal to Hood Inner Does not adequately prevent the - Design Study/Review
173 Minimize Air flow to Interior < 8 / 15 CFM per door based on VTS req Wind Noise, or excessive 5 P01 1. Improper material selected for seal 2 - Design Studies 2 20 Not at this time.
Sheet Metal intrusion of air into the cabin - FEA
Road Noise - Rapid prototypes
- SP Best Practice
- Mockups

- Prototype builds
- Benchmarking
Part allows dust Intrusion, - DVP&R
Dust Seal to Hood Inner Does not adequately prevent the - Design Study/Review
174 Minimize Air flow to Interior < 8 / 15 CFM per door based on VTS req Wind Noise, or excessive 5 P01 2. Incorrect seal base shape designed. 2 - Design Studies 2 20 Not at this time.
Sheet Metal intrusion of air into the cabin - FEA
Road Noise - Rapid prototypes
- SP Best Practice
- Mockups

- Benchmarking - Prototype builds

Part allows dust Intrusion,
Dust Seal to Hood Inner Does not adequately prevent the 3. Incorrect push pin locations specified (pin - Design Study/Review - Rapid prototypes Verify at Beta with different hole
175 Minimize Air flow to Interior < 8 / 15 CFM per door based on VTS req Wind Noise, or excessive 5 P01 2 5 50 SUP Steve Haar 1-Dec-19
Sheet Metal intrusion of air into the cabin spacing) - FEA - Mockups locations in seals
Road Noise
- SP Best Practice

-Benchmarking
- Prototype builds
- FEA study
VTS Performance based dB Increment. - DVP&R
Dust Seal to Hood Inner - Previous part history
176 Minimizing Noise Minimize road noise, wind noise and squeak Does not minimize NVH Squeak/itch noise 5 P01 1. Improper material selected for seal 2 - Design Studies 2 20 Not at thisa time
Sheet Metal - SAE callout
and rattle. - Rapid prototypes
- long term material studies
- Mockups
- SOR.

-Benchmarking
- Prototype builds
- FEA study
VTS Performance based dB Increment. - DVP&R
Dust Seal to Hood Inner - Previous part history
177 Minimizing Noise Minimize road noise, wind noise and squeak Does not minimize NVH Squeak/itch noise 5 P01 2. Incorrect seal base shape designed. 2 - Design Studies 2 20 Not at this time.
Sheet Metal - SAE callout
and rattle. - Rapid prototypes
- long term material studies
- Mockups
- SOR.

- Benchmarking - Prototype builds

VTS Performance based dB Increment. - Design Study/Review - DVP&R
Dust Seal to Hood Inner 3. Incorrect push pin locations specified (pin Verify at Beta with different hole
178 Minimizing Noise Minimize road noise, wind noise and squeak Does not minimize NVH Squeak/itch noise 5 P01 - FEA 2 - Design Studies 5 50 SUP Steve Haar 1-Dec-19
Sheet Metal spacing) locations in seals
and rattle. - SP Best Practice - Rapid prototypes
- Mockups

Ensure hand and / or tool clearance

Meet ergonomic requirements
Ensure ease of assembly and able to - Benchmarking
- Prototype builds
assemble - Design Study/Review
Dust Seal to Hood Inner Part causes ergonomic 1. Uncoordinated dimensions between pins - Mockups
179 Design for Assembly Ensure correct part orientation and correct Part is difficult to install 5 P01 - FEA 2 2 20 Not at this time.
Sheet Metal issues for operator to install on seals on hole in doors - Design verification on
part can be assembled - SP Best Practice
door.
Ensure no damage during assembly
Ensure part cannot be mis-assembled or
partially assembled.
Ensure hand and / or tool clearance
Meet ergonomic requirements
Ensure ease of assembly and able to - Benchmarking
assemble - Design Study/Review
Dust Seal to Hood Inner Part causes ergonomic - Prototype builds
180 Design for Assembly Ensure correct part orientation and correct Part is difficult to install 5 2. Incorrect pins in part - FEA 2 5 50 Not at this time.
Sheet Metal issues for operator to install - DVP&R
part can be assembled - SP Best Practice
Ensure no damage during assembly
Ensure part cannot be mis-assembled or
partially assembled.

- Benchmarking
- Prototype builds
Prevent / Manage Water Entry to Interior, Part allows dust Intrusion, 2. Inconsistent seal compression due to - Design Study/Review
Dust Seal to Fender Inner - Pressure Mapping
182 Sealing manage dust, CO, and contaminant Does not seal Wind Noise, or excessive 5 P01 varying sealing gap (not including seal gap - FEA 2 2 20 Not at this time.
Sheet Metal - Mockups
intrusion. Road Noise change) - SP Best Practice
- Design studies

Page 3 of 4
Printed: 7/21/2022 GM Confidential Rivan Hood Seals DFMEA 18FEB2021
 Design Failure Mode and Effects Analysis (DFMEA)
FMEA Name 2021 Rivian R1 FMEA #: FMEA Status: Open
Responsible Engineer: Abdul Baseer and Rob Ratekin Prepared by: K. Martin Complete Date:

Current Design
Current Design
Controls Action Item
Controls

New OCC

New RPN
New SEV

New DET
S O D R
Line No.

Potential Cause(s) (Design actions planned or Recommended Target

Marker
Class
Requirement / Specification Potential Failure Mode Potential Effect(s) (Analytical or physical Actions Taken Status
E / Mechanism(s) completed to prevent or reduce C E P Action(s) Responsibility Completion
Part / Interface Function (reference) (Loss of Function) of Failure occurrence of failure, provide details
validation method planned or (status description) (Open ,
V of Failure C T N (not already planned) Date
completed) Closed)
and Best Practices used)
Detection
Prevention

- Benchmarking
- Prototype builds
Prevent / Manage Water Entry to Interior, Part allows dust Intrusion, - Design Study/Review
Dust Seal to Fender Inner - Pressure Mapping
183 Sealing manage dust, CO, and contaminant Does not seal Wind Noise, or excessive 5 P01 3. Inadequate sealing surface - FEA 6 2 60 Not at this time.
Sheet Metal - Mockups
intrusion. Road Noise - SP Best Practice
- Design studies

- Benchmarking
- Prototype builds
Prevent / Manage Water Entry to Interior, Part allows dust Intrusion, - Design Study/Review
Dust Seal to Fender Inner - Pressure Mapping
184 Sealing manage dust, CO, and contaminant Does not seal Wind Noise, or excessive 5 4. Improper lip design - FEA 2 2 20 Not at this time.
Sheet Metal - Mockups
intrusion. Road Noise - SP Best Practice
- Design studies

- Benchmarking
- Prototype builds
Prevent / Manage Water Entry to Interior, Part allows dust Intrusion, - Design Study/Review
Dust Seal to Fender Inner 5. Inadequate design geometry of the lip, - Pressure Mapping
185 Sealing manage dust, CO, and contaminant Does not seal Wind Noise, or excessive 5 - FEA 2 2 20 Not a tthis time
Sheet Metal Shape/wall thickness. - Mockups
intrusion. Road Noise - SP Best Practice
- Design studies

- Benchmarking
- Prototype builds
Part allows dust Intrusion, 2. Inconsistent seal compression due to - Design Study/Review
Dust Seal to Fender Inner Does not adequately prevent the - Pressure Mapping
187 Minimize Air flow to Interior < 8 / 15 CFM per door based on VTS req Wind Noise, or excessive 5 P01 varying sealing gap (not including seal gap - FEA 2 2 20 Not at this time.
Sheet Metal intrusion of air into the cabin - Mockups
Road Noise change) - SP Best Practice
- Design studies

- Benchmarking
- Prototype builds
Part allows dust Intrusion, - Design Study/Review
Dust Seal to Fender Inner Does not adequately prevent the - Pressure Mapping
188 Minimize Air flow to Interior < 8 / 15 CFM per door based on VTS req Wind Noise, or excessive 5 3. Inadequate sealing surface - FEA 6 2 60 Not at this time.
Sheet Metal intrusion of air into the cabin - Mockups
Road Noise - SP Best Practice
- Design studies

- Benchmarking
- Prototype builds
Part allows dust Intrusion, - Design Study/Review
Dust Seal to Fender Inner Does not adequately prevent the - Pressure Mapping
189 Minimize Air flow to Interior < 8 / 15 CFM per door based on VTS req Wind Noise, or excessive 5 P01 4. Improper lip design (swing clearance) - FEA 2 2 20 Not this time
Sheet Metal intrusion of air into the cabin - Mockups
Road Noise - SP Best Practice
- Design studies

- Benchmarking
- Prototype builds
Part allows dust Intrusion, - Design Study/Review
Dust Seal to Fender Inner Does not adequately prevent the 5. Inadequate design geometry of the lip, - Pressure Mapping
190 Minimize Air flow to Interior < 8 / 15 CFM per door based on VTS req Wind Noise, or excessive 5 - FEA 2 2 20 Not at this time.
Sheet Metal intrusion of air into the cabin Shape/wall thickness. - Mockups
Road Noise - SP Best Practice
- Design studies

- Benchmarking
- Prototype builds
VTS Performance based dB Increment. 2. Inconsistent seal compression due to - Design Study/Review
Dust Seal to Fender Inner - Pressure Mapping
192 Minimizing Noise Minimize road noise, wind noise and squeak Does not minimize NVH Squeak/itch noise 5 P01 varying sealing gap (not including seal gap - FEA 2 2 20 Not at this time.
Sheet Metal - Mockups
and rattle. change) - SP Best Practice
- Design studies

- Benchmarking
- Prototype builds
VTS Performance based dB Increment. - Design Study/Review
Dust Seal to Fender Inner - Pressure Mapping
193 Minimizing Noise Minimize road noise, wind noise and squeak Does not minimize NVH Squeak/itch noise 5 P01 3. Improper lip design (swing clearance) - FEA 2 2 20 Not at this time.
Sheet Metal - Mockups
and rattle. - SP Best Practice
- Design studies

- Benchmarking
- Prototype builds
VTS Performance based dB Increment. - Design Study/Review
Dust Seal to Fender Inner 4. Inadequate design geometry of the lip, - Pressure Mapping
194 Minimizing Noise Minimize road noise, wind noise and squeak Does not minimize NVH Squeak/itch noise 5 - FEA 2 2 20 Not at this time.
Sheet Metal Shape/wall thickness. - Mockups
and rattle. - SP Best Practice
- Design studies

- Benchmarking
- Prototype builds
- Design Study/Review
Dust Seal to Fender Inner 1. Improper design geometry of the seal lip. - Pressure Mapping
195 Enable Low Closing Efforts < 3.0 Joules total system Door is difficult to close High closing efforts 5 - FEA 2 2 20 Not at this time.
Sheet Metal Shape/ thickness. - Mockups
- SP Best Practice
- Design studies

- Benchmarking
- Prototype builds
2. Inconsistent seal compression due to - Design Study/Review
Dust Seal to Fender Inner - Pressure Mapping
196 Enable Low Closing Efforts < 3.0 Joules total system Door is difficult to close High closing efforts 5 P01 varying sealing gap (not including seal gap - FEA 2 2 20 Not at this time.
Sheet Metal - Mockups
change) - SP Best Practice
- Design studies

- Benchmarking
- Design Study/Review - Prototype builds
Dust Seal to Fender Inner 3. Seal section design not robust to build
197 Enable Low Closing Efforts < 3.0 Joules total system Door is difficult to close High closing efforts 5 - FEA 4 - abrasion resistance 2 40 Not at this time.
Sheet Metal variation
- SP Best Practice testing

Ensure hand and / or tool clearance

Meet ergonomic requirements
Ensure ease of assembly and able to - Benchmarking
- Prototype builds
assemble - Design Study/Review
Part causes ergonomic 1. Uncoordinated dimensions between pins - Mockups
179 Aero Seal to Dust Seal Design for Assembly Ensure correct part orientation and correct Part is difficult to install 5 P01 - FEA 2 2 20 Not at this time.
issues for operator to install on seals on hole in doors - Design verification on
part can be assembled - SP Best Practice
door.
Ensure no damage during assembly
Ensure part cannot be mis-assembled or
partially assembled.
Ensure hand and / or tool clearance
Meet ergonomic requirements
Ensure ease of assembly and able to - Benchmarking
assemble - Design Study/Review
Part causes ergonomic - Prototype builds
180 Aero Seal to Dust Seal Design for Assembly Ensure correct part orientation and correct Part is difficult to install 5 2. Incorrect pins in part - FEA 2 5 50 Not at this time.
issues for operator to install - DVP&R
part can be assembled - SP Best Practice
Ensure no damage during assembly
Ensure part cannot be mis-assembled or
partially assembled.
Ensure hand and / or tool clearance
Meet ergonomic requirements
Ensure ease of assembly and able to - Benchmarking
assemble - Design Study/Review
Part causes ergonomic Incorrect desined tolerance gap between - Prototype builds
180 Aero Seal to Dust Seal Design for Assembly Ensure correct part orientation and correct Part is difficult to install 5 - FEA 2 5 50 Not at this time.
issues for operator to install parts - DVP&R
part can be assembled - SP Best Practice
Ensure no damage during assembly
Ensure part cannot be mis-assembled or
partially assembled.

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Printed: 7/21/2022 GM Confidential Rivan Hood Seals DFMEA 18FEB2021