{
  "opd": "benikigai/plus-one",
  "commit": 6,
  "opd_version": "0.5.0",
  "layer": "risk",
  "question": "What could go wrong, and how badly?",
  "data": {
    "pfmea": [
      {
        "id": "fm:stake-weak",
        "operation": "op:diffuser-stake",
        "failure_mode": "Stake under-melted; diffuser loose",
        "effect": "Ring rattles; light leaks at the seam",
        "cause": "Stake time or temperature low",
        "severity": 5,
        "occurrence": 4,
        "detection": 4,
        "evidence": [
          "src:tracker-puck-spec"
        ]
      },
      {
        "id": "fm:screw-strip",
        "operation": "op:board-screw",
        "failure_mode": "Screw strips the boss",
        "effect": "Board loose; button feel mushy",
        "cause": "Torque high or pilot hole oversize",
        "severity": 6,
        "occurrence": 3,
        "detection": 3,
        "evidence": [
          "src:tracker-puck-spec"
        ]
      },
      {
        "id": "fm:adhesive-on-cone",
        "operation": "op:adhesive-dispense",
        "failure_mode": "Adhesive bead touches the speaker cone",
        "effect": "Buzz or low output",
        "cause": "Bead placement drift",
        "severity": 6,
        "occurrence": 3,
        "detection": 4,
        "evidence": [
          "src:design-brief"
        ]
      },
      {
        "id": "fm:battery-unseat",
        "operation": "op:battery-mate",
        "failure_mode": "Battery connector half-seated",
        "effect": "Dead unit or resets after a drop",
        "cause": "Mate force low; in the factory simulation a 2 N tug let half-seated plugs through, so the check is now 3 N",
        "severity": 8,
        "occurrence": 4,
        "detection": 3,
        "evidence": [
          "src:ec-1-lessons",
          "src:factory-engine"
        ]
      },
      {
        "id": "fm:wire-pinch",
        "operation": "op:base-close",
        "failure_mode": "Battery lead pinched when the base closes",
        "effect": "Short; heat in the worst case",
        "cause": "Lead outside its channel",
        "severity": 9,
        "occurrence": 2,
        "detection": 4,
        "evidence": [
          "src:ec-1-lessons"
        ]
      },
      {
        "id": "fm:ring-polarity",
        "operation": "op:ring-bond",
        "failure_mode": "Magnet ring bonded flipped, or a segment missing",
        "effect": "Won't hold on a magnetic mount or charger",
        "cause": "Ring loaded upside down",
        "severity": 6,
        "occurrence": 3,
        "detection": 2,
        "evidence": [
          "src:design-brief"
        ]
      },
      {
        "id": "fm:coil-offset",
        "operation": "op:coil-place",
        "failure_mode": "Coil off-centre in the ring",
        "effect": "Slow or no wireless charging",
        "cause": "Coil not keyed to the base",
        "severity": 5,
        "occurrence": 3,
        "detection": 3,
        "evidence": [
          "src:design-brief"
        ]
      },
      {
        "id": "fm:pad-recessed",
        "operation": "op:pad-press",
        "failure_mode": "Pogo pad recessed",
        "effect": "Dock or module doesn't connect",
        "cause": "Pad not pressed to its stop",
        "severity": 5,
        "occurrence": 3,
        "detection": 2,
        "evidence": [
          "src:design-brief"
        ]
      },
      {
        "id": "fm:gasket-shift",
        "operation": "op:gasket-place",
        "failure_mode": "Mic gasket off its port",
        "effect": "Low mic sensitivity; poor wake word",
        "cause": "Gasket lifts with the liner",
        "severity": 6,
        "occurrence": 4,
        "detection": 3,
        "evidence": [
          "src:design-brief"
        ]
      },
      {
        "id": "fm:id-twice",
        "operation": "op:flash-provision",
        "failure_mode": "Unit ID provisioned twice or not at all",
        "effect": "Twin and QR point at the wrong unit",
        "cause": "Retry after a failed flash",
        "severity": 6,
        "occurrence": 2,
        "detection": 2,
        "evidence": [
          "src:design-brief"
        ]
      },
      {
        "id": "fm:rf-detune",
        "operation": "op:functional-test",
        "failure_mode": "Radio check passes a detuned antenna",
        "effect": "Short range in the field",
        "cause": "Module antenna near the ring LEDs or the cell",
        "severity": 6,
        "occurrence": 3,
        "detection": 5,
        "evidence": [
          "src:ec-1-lessons",
          "src:module-datasheet"
        ]
      },
      {
        "id": "fm:qr-unreadable",
        "operation": "op:laser-mark",
        "failure_mode": "QR unreadable",
        "effect": "Unit can't open its twin",
        "cause": "Laser focus or power drift",
        "severity": 3,
        "occurrence": 3,
        "detection": 2,
        "evidence": [
          "src:design-brief"
        ]
      }
    ]
  }
}