Introduction

Welcome to the FMEA Worksheet

This spreadsheet can be used to 1. Identify potential failure modes and their impact on product reliability. 2. Classez les dfauts potentiels selon leur criticit 3. Capture owners, action plans, and status on high RPN items. Note, FMEA's are living documents and this may be updated periodically. Organization of Spreadsheet: Descriptions - explains the spreadsheet cells FMEA - the actual sheet used to enter data Severity/Likelihood/Detectability - guidelines for the 1-10 rankins in these categories Example - a partial exmample of an FMEA document Sheet Protection: Some sheets are protected. There is no password.

Introduction

Descriptions

Description of FMEA Worksheet

Protection:The spreadsheets are not protected or locked.
System Subsystem Component Design Lead Core Team

Potential Failure Mode and Effects Analysis (Design FMEA)

Key Date

FMEA Number Prepared By FMEA Date Revision Date Page of

Action Results Potential Failure Potential Effect(s) Mode(s) of Failure S e v Potential Cause(s)/ Mechanism(s) of Failure Over pressure P r o b 8 Current Design Controls D e t R P N Recommended Action(s) Responsibility & Target Completion Date New RPN New Occ New Sev New Det

Item / Function

Actions Taken

Coolant containment. Hose connection. Coolant fill. M

Crack/break. Burst. Side wall flex. Bad seal. Poor hose rete

Leak

Burst, validation pressure cycle.

64 Test included in
prototype and production validation testing.

J.P. Aguire 11/1/95 E. Eglin 8/1/96

Write down each failure mode and potential consequence(s) of that failure. Severity - On a scale of 110, rate the Severity of each failure (10= most severe). See Severity sheet. Likelihood - Write down the potential cause(s), and on a scale of 1-10, rate the Likelihood of each failure (10= most likely). See

Response Plans and Tracking

Risk Priority Number - The combined weighting of Severity, Likelihood, and Detectability. RPN = Sev X Occ X Det

Detectability - Examine the current design, then, on a scale of 1-10, rate the Detectability of each failure (10 = least detectable). See Detectability sheet.

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System Subsystem Component Design Lead Core Team

Design Verification Process

Potential Failure Mode and Effects Analysis (Design FMEA)

Key Date

FMEA Number Prepared By FMEA Date Revision Date Page

Houston Mayer See Project III R1 Report

Project III Houston Mayer 10/22/1999 8/21/2000

1 of 6

Action Results Potential Failure Mode(s)

System, Software, Integration and Shipping requirements overlooked by customer. Data entry error

Item / Function

Potential Effect(s) of Failure

Customer needs not fully met by delivered system.

Potential P S D Cause(s)/ r Current Design e e Mechanism(s) o Controls v t of Failure b

7 Human error 1 Design configuration tool. 3

R P N

Recommended Action(s)

Responsibility & Target Actions Taken Completion Date

Closed 10/21/99

Customer sends in a quote request for product.

21 Use configuration tool when available.

Requirement entered and verified by Inside Sales in config. tool. Sales identifies need for CII or SHC

System compatability requirements not evaluated by config. tool. On time delivery and integraty of the product may be compramised if this issue is not addressed.

3 Human error

1 Order verified by a configuration tool.

9 Continue order verification by configuration tool. 63 Publish comprehensive procedure for the 1st Article Process.

Closed 10/21/99

Specific packing, labeling and shipping requirements may not be fully addressed.

7 Requirements Overlooked.

3 Customer Inspection Instruction/ Special Handling Codes Process 033-001-02 5 CII 033-001-006

Jun-00

Position of the Loss of business DHR in ICD with the label packet not customer. identified by GE. Requirment in Purchase Specification for mousepad, but not identified on Bill of Material. ICD Card content requirements not identified in Build Procedure. Houston Mayer Six Sigma Blackbelt August 21, 2000

1 Requirements Overlooked.

5 Revisit contents Sep-00 of GE CII 033001-006 to assure all requirements are clearly commumicated to the warehouse operators and quality technicians using these documents.

Customer shipping requirements reviewed by quality assurance in 1st Article process. OPEN 8/21/00

New RPN 4

New Occ

New Sev

New Det

QA and Pack and Ship Team reviews customer requirements during a 1st Article. Inside sales submits Sales Order Authorization request to TECenter.

Specific packing, labeling and shipping requirements may not be fully addressed.

Customer's full expectations may not be realized.

7 Requirements overlooked.

Data entry error Order Processing Delay

1 Human Error

3 Customer requirements physically verified by quality assurance during the 1st Article process. 1 Customer requirements verified by a TECenter engineer.

63 Continue Closed current pracices. 10/25/99

3 Continue current practices.

Closed 1/25/00

TECenter Requirements Engineer reviews overlooked by the design to Engineer determain if additional data is required. Appropriate individuals are contacted to resolve issues. Appropriate individuals not available.

Customer's full expectations may not be realized.

3 Requirements Overlooked.

6 Customer requirements verified by a TECenter engineer.

54 Continue current practices.

Closed 10/25/99

Order Processing Delay

1 Process Failure

1 Individuals are contacted to resolve issues.

1 Continue current practices.

Closed 1/25/00

Design Review is Requirements completed. may not be complete

Customer's full expectations may not be realized.

1 Process Failure

1 Customer requirements verified by a TECenter engineer. 3 Customer requirements verified by a TECenter engineer. 1 Verification is sent to appropriate organization. 1 Requirements are defined and to meet requirements.

1 Continue Closed 1/25/00 current pracices.

Another Requirements engineer overlooked by performs quality two Engineer check of the design. Completed Design design verification verification is misrouted sent to appropriate Requirements Requirements are defined and may be missed capability to or capibilty to meet/ accept meet Houston Mayer overestamated requirements. Six Sigma Blackbelt August 21, 2000

Customer's full expectations may not be realized.

7 Process Failure

63 Continue Closed current pracices. 10/25/99

Order Processing Delay

1 Process Failure

1 Continue Closed 1/25/00 current pracices.

Customer's full expectations may not be realized.

1 Process Failure

1 Continue Closed 1/25/00 current pracices.

Inside Sales Wrong price and Customer's full quotes price and availability expectations availability provided to may not be customer realized. Customer sends Order misrouted in purchase order. Inside sales Data Entry Error places order on system. Order approved by Asset Management. Order approved by credit. Determaination made that product is available for build. Approval not timely Approval not timely All product required for the order may not be available at the start of the build. Order Processing Delay Order Processing Delay Order Processing Delay Order Processing Delay (1) Product delivery date requirements may not be met. (2) Workspace occupied for an order awaiting Product is not available for integration of other orders. Customer's full expectations may not be realized. Order Processing Delay

3 Process Failure

1 Price provided to customer

3 Continue Closed 1/25/00 current pracices.

1 Process Failure 3 Human Error

1 Reprocess Order 1 Reprocess Order

1 1

1 Continue Closed 1/27/00 current pracices. 3 Continue Closed 1/27/00 current pracices. 1 Continue Closed 1/27/00 current pracices. 1 Continue Closed 1/27/00 current pracices. 15 Continue current practices. Closed 10/25/99

1 Process Failure

1 Expidite Process

1 Process Failure

1 Expidite Process

5 Needed components are not available at the time of need.

3 Assure product availability before the order commitment is given to customer.

Inside sales Shipdates may expedites with not be accurate Asset to provide ship date. Order approved by Asset Mgmt. and e-mail sent to Integration. Project Manager reviews order for special or internal instructions. e-mail may be misrouted

1 Needed components are not available at the time of need. 1 Process Failure

1 Expidite Process

1 Continue current practices.

Closed 1/27/00

1 Expidite Process

1 Continue current practices. 3 Continue current practices.

Closed 1/27/00

Order processing requirements may be overlooked

Customer and processing needs not identified could prevent timely processing of the order.

3 Processing requirements overlooked.

1 Project Manager order review.

Closed 10/25/99

Houston Mayer Six Sigma Blackbelt August 21, 2000

Build document Documents do bill of material not match matched with SCN.

Order Processing Delay

5 Needed components are not available at the time of need.

Stock availability is checked and delivery dates are aquired for non stock items. Order is forwarded to Production Engineer for review. Determanation made for a 1st Article build.

stock availability Customer's full and dates may expectations be inaccurate may not be realized. Order may be misrouted Order Processing Delay

3 Needed components are not available at the time of need. 1 Process Failure

3 Expidite Process 3 Integration Center Operations Manual 093-009OPSMNL 1 Expidite Process 1

45 Continue current practices.

Closed 1/27/00

3 Continue current practices.

Closed 1/27/00

1 Expidite Process

1 Continue current practices. 105 Continue current practices. 27 Continue current practices. 3 Continue current practices. 3 Continue current practices. 3 Continue current practices. 9 Continue current practices. 27 Continue current practices.

Continue current practices. Continue current practices. Continue current practices. Continue current practices. Closed 1/27/00

Need for 1st build may be overlooked

Build document Requirements is reviewed and may be verified. overlooked Project management notifies sales with status of order. Asset management places order for non stock items. Order is scheduled for production. Whse Operator reviews parts to SOA & SCN. Sales may not receive order status Items may not be ordered

Customer's full 7 expectations may not be realized. Customer's full 3 expectations may not be realized. Order 3 Processing Delay

Requirements Overlooked. Requirements Overlooked. Requirements Overlooked.

Individuals are contacted to resolve issues. Individuals are contacted to resolve issues. Individuals are contacted to resolve issues.

Order 3 Processing Delay

Needed 1 components are not available at the time of need. Requirements Overlooked. Requirements Overlooked. 1

Expidite Process 1

Order may not be entered in schedule Parts may not match requirement

Order 3 Processing Delay Order 3 Processing Delay

Individuals are contacted to resolve issues. Individuals are contacted to resolve issues. Individuals are contacted to resolve issues. Integration Kitting and Packing 153001-01

Closed 1/27/00

Closed 1/27/00

Whse. Operator All parts may Unpack,Iinspect not reach & Kit order. integration

Order 3 Processing Delay

All components 3 are not available at the time of need.

Closed 1/27/00

Houston Mayer Six Sigma Blackbelt August 21, 2000

Techs. Check product against SOW and build instructions. Integration Techs. inspect parts and chassis.

Parts may not match requirement

Order 5 Processing Delay

All components 3 are not available at the time of need. All components 3 are not available at the time of need. Requirements Overlooked. 1

Individuals are contacted to resolve issues. QA Inspection and Test Procedure 103001-03 QA Inspection and Test Procedure 103001-03

15 Continue current practices. 63 Continue current practices. 5 Update Build Procedures to clearly define product requirements specific to the model being integrated. 147 Continue current practices. 100 Continue current practices. 25 Continue current practices.

Closed 1/27/00

Materials may Order 7 not be compliant Processing Delay

Closed 1/27/00

No NT Resource Loss of business 1 Kit with the Missing Video customer. Board

Closed 8/21/00

Techs. Integrate System may be & Power-Up integrated System incorrectly Integration Techs. Test system. Quality techs. inspect product for build requirements.

Order 7 Processing Delay

Individuals are contacted to resolve issues.

QA Inspection and Test Procedure 103001-03

Closed 1/27/00

System and Order 10 Needed 10 QA Inspection parts may not be Processing Delay components are and Test compliant not available at Procedure 103the time of need. 001-03 Specific build requirements may not be fully addressed. On time delivery 5 and integraty of the product may be compramised if this issue is not addressed. Requirements Overlooked. 1 Individuals are contacted to resolve issues.

Closed 1/27/00

Houston Mayer Six Sigma Blackbelt August 21, 2000

IO panel not Loss of business 1 installed with the Label on CPU customer. Incorrect No feet or other components installed No extension cables Missing cables IO panel gasket not installed Wrong ICD cards provided Dome calibrater included

Human Error

Build Procedure 5 for individual PathSpeed Model

25 Update Build Procedures to clearly define product requirements specific to the model being integrated.

Closed 8/21/00

Product serial numbers scanned into Genesis. Change made after batch release

Numbers may be incorrect Control of requirements may be lost

Order 3 Processing Delay Order 1 Processing Delay Order 3 Processing Delay

Requirements Overlooked. Requirements Overlooked. Requirements Overlooked. Process Failure

Individuals are contacted to resolve issues. Individuals are contacted to resolve issues. Individuals are contacted to resolve issues. Individuals are contacted to resolve issues. Individuals are contacted to resolve issues.

9 Continue current practices. 1 Continue current practices. 9 Continue current practices. 3 Continue current practices. 7 Continue current practices.

Closed 1/27/00

Closed 1/27/00

Order placed on Shiping hold when deadlines may change is made. not be met Design Process reinitiates Whse. invoices and ships order per customer's shipping method. Quality techs. inspect shipment for CII/SHC requirements.

Closed 1/27/00

Control of Order 3 requirements Processing Delay may not be complete Wrong Shipping On time delivery 7 method may be and integraty of used the product may be compramised if this issue is not addressed. Specific packing, labeling and shipping requirements may not be fully addressed.

Closed 1/27/00

Process Failure

Closed 1/27/00

On time delivery 10 Requirements and integraty of Overlooked. the product may be compramised if this issue is not addressed.

Customer 3 Inspection Instruction/ Special Handling Codes Process 033-001-02

90 Continue Closed 1/25/00 current pracices.

Houston Mayer Six Sigma Blackbelt August 21, 2000

Label on outside Loss of business 1 of box did not with the match S/N on customer. CPU.

Human Error

CII 033-001-006 3

Product ships to Products customer. misshipped

On time delivery 7 and integraty of the product may be compramised if this issue is not addressed. Documents may 3 not be retrievable

Needed 3 components are not available at the time of need.

Individuals are contacted to resolve issues.

9 Revisit contents 9/11/2000 of GE CII 033001-006 to assure all requirements are clearly commumicated to the warehouse operators and quality technicians using these 147 Continue Closed 1/27/00 current practices.

Coordinator Documents not closes project & filed correctly files quality records.

Documents may 1 not be retrievable

Individuals are contacted to resolve issues.

3 Continue Closed 1/25/00 current pracices.

Houston Mayer Six Sigma Blackbelt August 21, 2000

10

Severity

Effect
Hazardous without warning Hazardous with warning Very High High Moderate Low Very Low Minor Very Minor None

SEVERITY of Effect
Very high severity ranking when a potential failure mode affects safe system operation without warning Very high severity ranking when a potential failure mode affects safe system operation with warning System inoperable with destructive failure without compromising safety System inoperable with equipment damage System inoperable with minor damage System inoperable without damage System operable with significant degradation of performance System operable with some degradation of performance System operable with minimal interference No effect

Ranking 10 9 8 7 6 5 4 3 2 1

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Severity

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Severity

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Severity

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Severity

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Severity

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Severity

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Severity

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Probability

PROBABILITY of Failure
Very High: Failure is almost inevitable

Failure Prob Ranking >1 in 2 10

1 in 3

9 8 7 6 5 4 3 2 1

High: Repeated failures

1 in 8 1 in 20

Moderate: Occasional failures

1 in 80 1 in 400 1 in 2,000

Low: Relatively few failures

1 in 15,000 1 in 150,000

Remote: Failure is unlikely

<1 in 1,500,000

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Detectability

Detection
Absolute Uncertainty Very Remote Remote Very Low Low Moderate Moderately High High Very High Almost Certain

Ranking Design control cannot detect potential cause/mechanism and 10

subsequent failure mode Very remote chance the design control will detect potential cause/mechanism and subsequent failure mode Remote chance the design control will detect potential cause/mechanism and subsequent failure mode Very low chance the design control will detect potential cause/mechanism and subsequent failure mode Low chance the design control will detect potential cause/mechanism and subsequent failure mode Moderate chance the design control will detect potential cause/mechanism and subsequent failure mode Moderately High chance the design control will detect potential cause/mechanism and subsequent failure mode High chance the design control will detect potential cause/mechanism and subsequent failure mode Very high chance the design control will detect potential cause/mechanism and subsequent failure mode Design control will detect potential cause/mechanism and subsequent failure mode

Likelihood of DETECTION by Design Control

9 8 7 6 5 4 3 2 1

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EXAMPLE

System Subsystem Component Design Lead Core Team

Potential Failure Mode and Effects Analysis (Design FMEA)

Item / Function

Potential Failure Mode(s)

Seals Coolant containment. Hose connection. Coolant fill. M Sensor mount. Seal Sensor mount. Seal Compression set Loosen during sensor assembly/servic e

Sensor mount. Seal

Damaged internal thread

Sensor mount. Seal

Damaged external thread

Coolant containment. Crack/break. Burst. Hose connection. Side wall flex. Bad Coolant fill. M seal. Poor hose rete

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EXAMPLE

System Subsystem Component Design Lead Core Team

Potential Failure Mode and Effects Analysis (Design FMEA)

Item / Function

Potential Failure Mode(s)

Coolant containment. Crack/break. Burst. Hose connection. Side wall flex. Bad Coolant fill. M seal. Poor hose rete Coolant containment. Crack/break. Burst. Hose connection. Side wall flex. Bad Coolant fill. M seal. Poor hose rete Hold fluid, flow path, Heat transfer structure Stress crack

Hold fluid, flow path, Heat transfer structure

Stress crack

Hold fluid, flow path, Heat transfer structure Hold fluid, flow path, Heat transfer structure Hold fluid, flow path, Heat transfer structure

Stress crack

Corrosion

Corrosion

Hold fluid, flow path, Heat transfer structure

Puncture

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EXAMPLE

System Subsystem Component Design Lead Core Team

Potential Failure Mode and Effects Analysis (Design FMEA)

Item / Function

Potential Failure Mode(s) Seam fail

Hold fluid, flow path, Heat transfer structure Hold fluid, flow path, Heat transfer structure Hold fluid, flow path, Heat transfer structure Hold fluid, flow path, Heat transfer structure

Burst fail

Plugged

Ballooning

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EXAMPLE

Potential Failure Mode and Effects Analysis (Design FMEA)

Key Date

FMEA Number Prepared By FMEA Date Revision Date Page of

Action Results Potential Effect(s) of Failure S e v Potential Cause(s)/ Mechanism(s) of Failure P r o b Current Design Controls D e t R P N Recommended Action(s) Responsibility & Target Completion Date New RPN New Occ New Sev New Det

Actions Taken

Leak Leak. Fall inside tank

8 Gasket material 8 Fitting not held in place

7 Pressure cycle w/cold shock. 2 Added rib.

1 1

56 Use imported material 16 Implement holding rib in design. New fitting design. Prototype validation. 10 J.P. Aguire 11/1/95

Cannot install sensor

5 Damaged during installation or transportation 4 Damaged during shipment to piracicaba

8 Over pressure 8

Cannot install wire nut

12 Damaged fitting not used by Piracicaba 64 Test included in

J.P. Aguire 11/1/95 prototype and E. Eglin 8/1/96 production validation testing.

Leak

Burst, validation pressure cycle.

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EXAMPLE

Potential Failure Mode and Effects Analysis (Design FMEA)

Key Date

FMEA Number Prepared By FMEA Date Revision Date Page of

Action Results Potential Effect(s) of Failure Failed mount S e v 5 Potential Cause(s)/ Mechanism(s) of Failure Vibration P r o b 9 Current Design Controls Vibration w/road tapes D e t 3 R P N Recommended Action(s) Responsibility & Target Completion Date New RPN New Occ New Sev New Det

Actions Taken

135 Obtain GMB vibration J.P. Aguire

road tape.

Hose leak

Overpressure. Poor clamp

Burst, validation pressure cycle w/GMB clamps.

60 Obtain GMB clamps

and clamping specification. Operator instruction

J.P. Aguire 12/1/95

Air conditioning does not work. Sudden refrigerant loss.

Air conditioning does not work. Sudden refrigerant loss.

Leak. Loss of heat transfer. Air conditioning does not work. Sudden refrigerant loss. Leak. Loss of heat transfer.

This is a test of the ADD POTENTIAL CAUSE/MECHANIS M OF FAILURE system functionality This is a test of the ADD POTENTIAL CAUSE/MECHANIS M OF FAILURE system functionality Wicking. Material strength this is a test while dan is here

Thermal cycle

This is a test of the ADD RECOMMENDED ACTION system functionality 56 Included in Product Specification

E. Eglin 8/1/96

Coolant quality. 7 Contamination. Environment - int/ext.

SWAT, service simulation. Coolant evaluation.

280 Brazilian coolant to

be evaluated. Zince lined tubes may need to be released. Simulated service test w/GMB coolant to be performed.

J.P. Aguirre 11/1/95 Coolant ordered

Leak. Loss of heat transfer.

External damage. Coolant velocity. No reinf sawcut.

10

Leak test. Simulated service.

80 100% cores tested in E. Eglin 8/1/96

production. Simulated service included in Product Specificatin.

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EXAMPLE

Potential Failure Mode and Effects Analysis (Design FMEA)

Key Date

FMEA Number Prepared By FMEA Date Revision Date Page of

Action Results Potential Effect(s) of Failure Leak. Loss of heat transfer. Leak. Loss of heat transfer. S e v 5 Potential Cause(s)/ Mechanism(s) of Failure P r o b Current Design Controls SWAT, service simulation. Burst/leak pressure D e t 1 R P N Recommended Action(s) Responsibility & Target Completion Date E. Eglin 8/1/96 New RPN New Occ New Sev New Det

Actions Taken

Environment - int/ext. 1

5 Included in Product
Specification.

Over pressure contamination. Contamination. Coolant quality.

80 GMB to study engine GMB 12/1/95

cleanliness.

Study originated

Loss of heat transfer. 8 Leakage due to increase flow velocity Leak. Loss of heat transfer. 5

Over pressure contamination.

J.P. Aguirre 11/1/95 Coolant ordered evaluated. GMB to study engine cleanliness. 360 GMB to study engine GMB 12/1/95 cleanliness. Clustomer profile to be determined.

56 GMB coolant to be

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