Item No.

Process:

Prepared By:

Process Responsibility:

Process Function/Requirement
Failure Mode and Effects Analysis

Potential Failure Mode

System FMEA

S
Potential Effect(s) of Failure e
v

10

2
 FMEA Reference Number:

Page:

FMEA Date (Orig):

C
l
a Potential Failure Cause
s
s
 1 of

(Rev):

Current Process Controls

O D
Prevention Controls c Detection Controls e
c t
10 10

4 4

2 2
 R&D

RPN Recommended Action

Responsible Target Completion Date

1000
0
0
64
0
0
8
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
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0
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0
0
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 Action Results

Actions eS O D
c e RPN
Taken v c t
0
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 Failure Mode and Effects Analysis Design FMEA
FMEA Reference Number:
Process:
Page: 1 of
Prepared By:
FMEA Date (Orig): (Rev):
Process Responsibility:

C Current Process Controls R&D Action Results

S l
Item No. Process Function/Requirement Potential Failure Mode Potential Effect(s) of Failure e a Potential Failure Cause RPN Recommended Action
v s O D S O D
Prevention Controls c Detection Controls e Responsible Target Completion Date Actions e c e RPN
s Taken v
c t c t
10 10 10 1000 0
0 0
0 0
4 4 4 64 0
0 0
0 0
2 2 2 8 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
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0 0
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0 0
 Failure Mode and Effects Analysis Process FMEA
FMEA Reference Number:
Process:
Page: 1 of
Prepared By:
FMEA Date (Orig): (Rev):
Process Responsibility:

C Current Process Controls R&D Action Results

S l
Process No. Process Function/Requirement Potential Failure Mode Potential Effect(s) of Failure e a Potential Failure Cause RPN Recommended Action
v s O D S O
Prevention Controls c Detection Controls e Responsible Target Completion Date Actions e c
s Taken
c t v c
10 10 10 1000
 Process:

Prepared By:

Process Responsibility:

Item No. Process Function/Requirement

Failure Mode and Effects Analysis Machine FMEA

S
Potential Failure Mode Potential Effect(s) of Failure e
v

10

2
 FMEA Reference Number:

Page: 1 of

FMEA Date (Orig): (Rev):

C Current Process Controls

l
a Potential Failure Cause
s O
s Prevention Controls c Detection Controls
c
10

2
 R&D Action Results

RPN Recommended Action

D Actions eS O D
e Responsible Target Completion Date c e
Taken v
t c t
10 1000
0
0
4 64
0
0
2 8
0
0
0
0
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RPN

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 1 not perceptible
2 small
3 small
4 medium
5 medium
significance
6 medium
7 significant
8 significant
9 very significant
10 very significant
1 very probable
2 probable
3 medium
4 medium
5 medium
detection
6 small
7 small
8 small
9 very small
10 improbable
1 improbable
2 very small
3 very small
4 small
5 small
occurrence
6 small
7 medium
8 medium
9 high
10 high

1 None
2 Very Minor
3 Minor
4 Very Low
5 Low
significance
6 Moderate
7 High
8 Very High
9 Hazardous-with warning
10 Hazardous-without warning
1 Almost Certain
2 Very High
3 High
4 Moderately High
5 Moderate
detection
6 Low
7 Very Low
 detection

8 Remote
9 Very Remote
10 Absolute Uncertainty
1 Remote
2 Low
3 Low
4 Moderate
5 Moderate
occurrence
6 Moderate
7 High
8 High
9 Very High
10 Very High

1 None
2 Very Minor
3 Minor
4 Very Low
5 Low
significance
6 Moderate
7 High
8 Very High
9 Hazardous-with warning
10 Hazardous-without warning
1 Almost Certain
2 Very High
3 High
4 Moderately High
5 Moderate
detection
6 Low
7 Very Low
8 Remote
9 Very Remote
10 Almost impossible
1 Remote
2 Very Low
3 Low
4 Moderate
5 Moderate
occurrence
6 Moderate
7 High
8 High
9 Very High
10 Very High
not perceptible It is improbable that this failure will result in a perceptible change in the perform
small This failure is not significant. The customer will not be inconvenienced by a the malfunction
small This failure is not significant. The customer will not be inconvenienced by a the malfunction
medium This failure is significant enough to inconvenience or angry the customer. He or she will
medium This failure is significant enough to inconvenience or angry the customer. He or she will
medium This failure is significant enough to inconvenience or angry the customer. He or she will
significant Significant failure that causes a total malfunction of the system. The customer will not
significant Significant failure that causes a total malfunction of the system. The customer will not
very significant Significant failure that causes total inoperabilty of the system and possible malfu
very significant Significant failure that causes total inoperabilty of the system and possible malfu
very probable It is improbable that the failure will not be recognized during testing. Chance of di
probable It is improbable that the failure will not be recognized during testing. Chance of discove
medium Chance of discovery >= 99.7%.
medium Chance of discovery >= 99.7%.
medium Chance of discovery >= 99.7%.
small Chance of discovery >= 98%.
small Chance of discovery >= 98%.
small Chance of discovery >= 98%.
very small Chance of discovery >= 90%
improbable Chance of discovery < 90%
improbable It is improbable for this failure to occur. Chance of failure <= 1/100000
very small This design is only slightly different from earlier proven designs. Chance of failure <=
very small This design is only slightly different from earlier proven designs. Chance of failure <=
small This design is only slightly different from earlier proven designs which failed in some cases
small This design is only slightly different from earlier proven designs which failed in some cases
small This design is only slightly different from earlier proven designs which failed in some cases
medium This design is only slightly different from earlier proven designs which caused problems
medium This design is only slightly different from earlier proven designs which caused problems
high This design is almost certain to cause problems. Chance of failure <= 1/10
high This design is almost certain to cause problems. Chance of failure <= 1/2

No Effect
Fit & Finish/Squeak & Rattle item does not conform. Defect noticed by discriminating customer.
Minor Fit & Finish/Squeak & Rattle item does not conform. Defect noticed by average customer.
Very Low Fit & Finish/Squeak & Rattle item does not conform. Defect noticed by most customers.
Low Vehicle/item operable, but Comfort/Convenience item(s) operable at reduced level of perform
Moderate Vehicle/item operable, but Comfort/Convenience item(s) inoperable. Customer experien
High Vehicle/item operable, but at reduced level of performance. Customer dissatisfied.
Very High Vehicle/item inoperable, with loss of primary function.
Hazardous-with warning Very high severity ranking when a potential failure mode affects safe veh
Hazardous-without warning Very high severity ranking when a potential failure mode affects safe
Almost Certain Design Control will almost certainly detect a potential cause/mechanism and subs
Very High Very high chance the Design Control will detect a potential cause/mechanism and subs
High High chance the Design Control will detect a potential cause/mechanism and subsequent fai
Moderately High Moderately high chance the Design Control will detect a potential cause/mechan
Moderate Moderate chance the Design Control will detect a potential cause/mechanism and subs
Low Low chance the Design Control will detect a potential cause/mechanism and subsequent failu
Very Low Very low chance the Design Control will detect a potential cause/mechanism and subseq
Remote Remote chance the Design Control will detect a potential cause/mechanism and subsequ
Very Remote Very remote chance the Design Control will detect a potential cause/mechanism and
Absolute Uncertainty Design Control will not and/or can not detect a potential cause/mechanism a
Remote Failure is unlikely Possible Failure Rate <=1 in 1,500,000
Low Relatively few failures Possible Failure Rate 1 in 150,000
Low Relatively few failures Possible Failure Rate 1 in 15,000
Moderate Occasional failures Possible Failure Rate 1 in 2,000
Moderate Occasional failures Possible Failure Rate 1 in 400
Moderate Occasional failures Possible Failure Rate 1 in 80
High Repeated failures Possible Failure Rate 1 in 20
High Repeated failures Possible Failure Rate 1 in 8
Very High Failure is almost inevitable Possible Failure Rate 1 in 3
Very High Failure is almost inevitable Possible Failure Rate >=1 in 2

None No Effect.
Very Minor Minor disruption to production line. A portion (less than 100%) of the product may hav
Minor Minor disruption to production line. A portion (less than 100%) of the product may have to b
Very Low Minor disruption to production line. The product may have to be sorted and a portion (le
Low Minor disruption to production line. 100% of product may have to be reworked. Fit & Finish/Sq
Moderate Minor disruption to production line. A portion (less than 100%) of the product may have
High Minor disruption to production line. Product may have to be sorted and a portion (less than
Very High Major disruption to production line. 100% of product may have to be scrapped. Vehicle
Hazardous-with warning May endanger machine of assembly operator. Very high severity ranking
Hazardous-without warning May endanger machine of assembly operator. Very high severity rank
Almost Certain Design control(s) almost certain to detect the failure mode. Reliable detectio
Very High Very high likelihood current control(s) will detect failure mode.
High High likelihood current control(s) will detect failure mode.
Moderately High Moderately high likelihood current control(s) will detect failure mode.
Moderate Moderate likelihood current control(s) will detect failure mode.
Low Low likelihood current control(s) will detect failure mode.
Very Low Very low likelihood current control(s) will detect failure mode.
Remote Remote likelihood current control(s) will detect failure mode.
Very Remote Very remote likelihood current control(s) will detect failure mode.
Almost impossible No known control(s) available to detect failure mode.
Remote Failure is unlikely. No failures ever associated with almost identical processes.
Very Low Only isolated failures associated with almost identical processes. Possible Failure Rate 1
Low Isolated failures associated with similar processes. Possible Failure Rate 1 in 15,000 Cpk >=
Moderate Generally associated with processes similar to previous processes which have experien
Moderate Generally associated with processes similar to previous processes which have experien
Moderate Generally associated with processes similar to previous processes which have experien
High Generally associated with processes similar to previous processes that have often failed. Po
High Generally associated with processes similar to previous processes that have often failed. Po
Very High Failure is almost inevitable. Possible Failure Rate 1 in 3 Cpk >= 0.33
Very High Failure is almost inevitable. Possible Failure Rate >= 1 in 2 Cpk < 0.33