Potential Page 1 of 76

Failure Mode and Effects Analysis

http://www.qimacros.com/free-lean-six-sigma-tips/fmea.html (Design FMEA)
System: Name/number of system
Subsystem Name/number of subsystem Design
Component Name/number of component Responsibility: Name
Model: model years/programs Key Date: 7/15/2008
Core Team: Team members
Item/Function

Occurrence

Detection
Potential

Severity
Current Design Current Design R.

Class
Potential Effect(s) Cause(s) /
Potential Failure Mode Controls Controls P.
of Failure Mechanism(s) of N.
Prevention Detection
Failure
Requirements
Name, Part Manner in which part could Consequences on List every List prevention List detection
Number, or fail: cracked, loosened, other systems, potential cause activities to activities to
Class deformed, leaking, oxidized, parts, or people: and/or failure assure design assure design
etc. noise, unstable, mechanism: adequacy and adequacy and
Function inoperative, incorrect material, prevent or prevent or
impaired, etc. improper reduce reduce
maintenance, occurrence. occurrence.
fatigue, wear, etc.
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
 Page 2 of 76

Potential
Failure Mode and Effects Analysis
http://www.qimacros.com/free-lean-six-sigma-tips/fmea.html (Design FMEA)
System: Name/number of system
Subsystem Name/number of subsystem Design
Component Name/number of component Responsibility: Name
Model: model years/programs Key Date: 7/15/2008
Core Team: Team members
Item/Function

Occurrence

Detection
Potential

Severity
Current Design Current Design R.

Class
Potential Effect(s) Cause(s) /
Potential Failure Mode Controls Controls P.
of Failure Mechanism(s) of N.
Prevention Detection
Failure
Requirements
0
0
0
0
Severity of Effect: Occurrence Rating Detection:
No Effect 1. None 1. Very low <.01/1000 1. Almost Certain
2. Very Minor 2. Low - 1/1000000 2. Very High
Annoyance 3. Minor 3. Low - 1/100000 3. High
4. Very Low 4. Moderate - 1/10000 4. Moderate High
Loss or degradation 5. Low 5. Moderate - 1/2000 5. Moderate
of secondary function 6. Moderate 6. Moderate - 1/500 6. Low
Loss or degradation 7. High 7. High - 1/100 7. Very Low
of primary function 8. Very High 8. High - 1/50 8. Remote
Failure to meet 9. Hazardous with warning 9. Very High 1/20 9. Very Remote
safety/regulations 10. Hazardous w/o warning 10. Very High >1/10 10. Almost Impossible
 Page 3 of 76

AIAG Fourth Edition http://www.aiag.org/ SAE J1739

FMEA Number Insert FMEA#
Page 1 of 1
Prepared by: who
FMEA Date: 7/15/2008

Action Results

Occurrence
Detection
Severity
Responsibility & R.
Recommended Actions Taken &
Target Completion P.
Action(s) Completion Date N.
Date

Design actions to Name of Actions and

reduce severity, organization or actual completion
occurrence and individual and date
detection ratings. target completion
Severity of 9 or date
10 requires
special attention.

0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
 Page 4 of 76

AIAG Fourth Edition http://www.aiag.org/ SAE J1739

FMEA Number Insert FMEA#
Page 1 of 1
Prepared by: who
FMEA Date: 7/15/2008

Action Results

Occurrence
Detection
Severity
Responsibility & R.
Recommended Actions Taken &
Target Completion P.
Action(s) Completion Date N.
Date

0
0
0
0
Stakeholder Effects of Failure Severity
Consumer Owner Safety Problem 10
(e.g., buyer) Major Owner Dissatisfaction 8
Moderate Owner Dissatisfaction 6
Minor Owner Dissatisfaction 4
Customer Plant Safety Problem 10
(Manufacturer) Possible Recal 9
Line Stoppage 8
Warranty Costs 7
AIAG PPAP 4th Scrap 7
Regulatory Penalty 7
Moderate Rework (<25%) 5
Plant Dissatisfaction 4
Minor Rework (<10%) 3
 Potential Page 5 of 76
Failure Mode and Effects Analysis
http://www.qimacros.com/free-lean-six-sigma-tips/fmea.html (Design FMEA)
System: Name/number of system
Subsystem Name/number of subsystem Design
Component Name/number of component Responsibility: Name
Model: model years/programs Key Date: 7/15/2008
Core Team: Team members
Item/Part

Occurrence
Potential

Severity
Current Design

Class
Potential Effect(s) Cause(s) /
Requirements Potential Failure Mode Controls
of Failure Mechanism(s) of
Prevention
Failure
Function
Name, Part Requirements Manner in which part could Consequences on List every List prevention
Number, or of function fail: cracked, loosened, other systems, potential cause activities to
Class being analyzed deformed, leaking, oxidized, parts, or people: and/or failure assure design
etc. noise, unstable, mechanism: adequacy and
Function inoperative, incorrect material, prevent or
impaired, etc. improper reduce
maintenance, occurrence.
fatigue, wear, etc.
 Page 6 of 76

Potential
Failure Mode and Effects Analysis
http://www.qimacros.com/free-lean-six-sigma-tips/fmea.html (Design FMEA)
System: Name/number of system
Subsystem Name/number of subsystem Design
Component Name/number of component Responsibility: Name
Model: model years/programs Key Date: 7/15/2008
Core Team: Team members
Item/Part

Occurrence
Potential

Severity
Current Design

Class
Potential Effect(s) Cause(s) /
Requirements Potential Failure Mode Controls
of Failure Mechanism(s) of
Prevention
Failure
Function

Severity of Effect: Occurrence Rating

No Effect
Annoyance
Loss or degradation
of secondary function
Loss or degradation
of primary function
Failure to meet
safety/regulations
1. None 1. Very low <.01/1000
2. Very Minor 2. Low - 1/1000000
3. Minor 3. Low - 1/100000
4. Very Low 4. Moderate - 1/10000
5. Low 5. Moderate - 1/2000
6. Moderate 6. Moderate - 1/500
7. High 7. High - 1/100
8. Very High 8. High - 1/50
9. Hazardous with warning 9. Very High 1/20
10. Hazardous w/o warning 10. Very High >1/10
 Potential Page 7 of 76
Failure Mode and Effects Analysis
(Design FMEA) AIAG Fourth Edition http://www.aiag.org/
FMEA Number Insert FMEA#
Page 1 of 1
Prepared by: who
FMEA Date: 7/15/2008

Action Results

Occurrence
Detection

Detection
Severity
Current Design R. Responsibility & R.
Recommended Actions Taken &
Controls P. Target Completion P.
N. Action(s) Completion Date N.
Detection Date

List detection Design actions to Name of Actions and

activities to reduce severity, organization or actual completion
assure design occurrence and individual and date
adequacy and detection ratings. target completion
prevent or Severity of 9 or date
reduce 10 requires
occurrence. special attention.

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 0
0 0
0 0
0 0
0 0
0 0
0 0
 Page 8 of 76

Potential
Failure Mode and Effects Analysis
(Design FMEA) AIAG Fourth Edition http://www.aiag.org/
FMEA Number Insert FMEA#
Page 1 of 1
Prepared by: who
FMEA Date: 7/15/2008

Action Results

Occurrence
Detection

Detection
Severity
Current Design R. Responsibility & R.
Recommended Actions Taken &
Controls P. Target Completion P.
N. Action(s) Completion Date N.
Detection Date

0 0
0 0
0 0
0 0
Detection: Stakeholder Effects of Failure Severity
1. Almost Certain Consumer Owner Safety Problem 10
2. Very High (e.g., buyer) Major Owner Dissatisfaction 8
3. High Moderate Owner Dissatisfaction 6
4. Moderate High Minor Owner Dissatisfaction 4
5. Moderate Customer Plant Safety Problem 10
6. Low (Manufacturer) Possible recall 9
7. Very Low Line Stoppage 8
8. Remote Warranty Costs 7
9. Very Remote AIAG PPAP 4th Scrap 7
10. Almost Impossible Regulatory Penalty 7
Moderate Rework (<25%) 5
Plant Dissatisfaction 4
Minor Rework (<10%) 3
 Potential Page 9 of 76
Failure Mode and Effects Analysis
http://www.qimacros.com/free-lean-six-sigma-tips/fmea.html (Design FMEA)
System: Name/number of system
Subsystem Name/number of subsystem Design
Component Name/number of component Responsibility: Name
Model: model years/programs Key Date: 7/15/2008
Core Team: Team members
Item/Function

Occurrence

Detection
Potential

Severity
Current Design Current Design R.

Class
Potential Effect(s) Cause(s) /
Potential Failure Mode Controls Controls P.
of Failure Mechanism(s) of N.
Prevention Detection
Failure
Requirements
Name, Part Manner in which part could Consequences on List every List prevention List detection
Number, or fail: cracked, loosened, other systems, potential cause activities to activities to
Class deformed, leaking, oxidized, parts, or people: and/or failure assure design assure design
etc. noise, unstable, mechanism: adequacy and adequacy and
Function inoperative, incorrect material, prevent or prevent or
impaired, etc. improper reduce reduce
maintenance, occurrence. occurrence.
fatigue, wear, etc.
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
 Page 10 of 76

Potential
Failure Mode and Effects Analysis
http://www.qimacros.com/free-lean-six-sigma-tips/fmea.html (Design FMEA)
System: Name/number of system
Subsystem Name/number of subsystem Design
Component Name/number of component Responsibility: Name
Model: model years/programs Key Date: 7/15/2008
Core Team: Team members
Item/Function

Occurrence

Detection
Potential

Severity
Current Design Current Design R.

Class
Potential Effect(s) Cause(s) /
Potential Failure Mode Controls Controls P.
of Failure Mechanism(s) of N.
Prevention Detection
Failure
Requirements
0
0
0
0
Severity of Effect: Occurrence Rating Detection:
No Effect 1. None 1. Very low <.01/1000 1. Almost Certain
2. Very Minor 2. Low - 1/1000000 2. Very High
Annoyance 3. Minor 3. Low - 1/100000 3. High
4. Very Low 4. Moderate - 1/10000 4. Moderate High
Loss or degradation 5. Low 5. Moderate - 1/2000 5. Moderate
of secondary function 6. Moderate 6. Moderate - 1/500 6. Low
Loss or degradation 7. High 7. High - 1/100 7. Very Low
of primary function 8. Very High 8. High - 1/50 8. Remote
Failure to meet 9. Hazardous with warning 9. Very High 1/20 9. Very Remote
safety/regulations 10. Hazardous w/o warning 10. Very High >1/10 10. Almost Impossible
 Page 11 of 76

AIAG Fourth Edition http://www.aiag.org/

FMEA Number Insert FMEA#
Page 1 of 1
Prepared by: who
FMEA Date: 7/15/2008

Action Results

Occurrence
Detection
Severity
Responsibility & R.
Recommended Actions Taken &
Target Completion P.
Action(s) Completion Date N.
Date

Design actions to Name of Actions and

reduce severity, organization or actual completion
occurrence and individual and date
detection ratings. target completion
Severity of 9 or date
10 requires
special attention.

0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
 Page 12 of 76

AIAG Fourth Edition http://www.aiag.org/

FMEA Number Insert FMEA#
Page 1 of 1
Prepared by: who
FMEA Date: 7/15/2008

Action Results

Occurrence
Detection
Severity
Responsibility & R.
Recommended Actions Taken &
Target Completion P.
Action(s) Completion Date N.
Date

0
0
0
0
Stakeholder Effects of Failure Severity
Consumer Owner Safety Problem 10
(e.g., buyer) Major Owner Dissatisfaction 8
Moderate Owner Dissatisfaction 6
Minor Owner Dissatisfaction 4
Customer Plant Safety Problem 10
(Manufacturer) Possible Recall 9
Line Stoppage 8
Warranty Costs 7
AIAG PPAP 4th Scrap 7
Regulatory Penalty 7
Moderate Rework (<25%) 5
Plant Dissatisfaction 4
Minor Rework (<10%) 3
 Potential Page 13 of 76
Failure Mode and Effects Analysis
http://www.qimacros.com/free-lean-six-sigma-tips/fmea.html (Design FMEA)
System: Name/number of system
Subsystem Name/number of subsystem Design
Component Name/number of component Responsibility: Name
Model Years: model years/programs Key Date: 7/15/2008 7/15/08 Rev
Core Team: Team members
Item/Part Current Design

Occurrence

Detection
Potential

Severity
Potential Current Design Current Design

Class
Potential Failure Cause(s) /
Requirements Effect(s) of Controls Controls
Mode Mechanism(s) of
Failure Prevention Detection
Failure
Function
Name, Part Requirements of Manner in which Effects of failure List every List prevention List detection
Number, or function being system/subsystem as perceived by potential cause activities to activities to
Class analyzed /component could customers. and/or failure assure design assure design
fail: cracked, Consequences mechanism: adequacy and adequacy and
Function loosened, on other incorrect material, prevent or prevent or
deformed, leaking, systems, parts, improper reduce reduce
oxidized, etc. or people: noise, maintenance, occurrence. occurrence.
inoperative, fatigue, wear, etc.
impaired, etc.
 Page 14 of 76

Potential
Failure Mode and Effects Analysis
http://www.qimacros.com/free-lean-six-sigma-tips/fmea.html (Design FMEA)
System: Name/number of system
Subsystem Name/number of subsystem Design
Component Name/number of component Responsibility: Name
Model Years: model years/programs Key Date: 7/15/2008 7/15/08 Rev
Core Team: Team members
Item/Part Current Design

Occurrence

Detection
Potential

Severity
Potential Current Design Current Design

Class
Potential Failure Cause(s) /
Requirements Effect(s) of Controls Controls
Mode Mechanism(s) of
Failure Prevention Detection
Failure
Function

Severity of Effect: Occurrence Rating Detection:

No Effect 1. None 1. Very low <.01/1000 1. Almost Certain
2. Very Minor 2. Low - 1/1000000 2. Very High
Annoyance 3. Minor 3. Low - 1/100000 3. High
4. Very Low 4. Moderate - 1/10000 4. Moderate High
Loss or degradation 5. Low 5. Moderate - 1/2000 5. Moderate
of secondary function6. Moderate 6. Moderate - 1/500 6. Low
Loss or degradation 7. High 7. High - 1/100 7. Very Low
of primary function 8. Very High 8. High - 1/50 8. Remote
Failure to meet 9. Hazardous with warning 9. Very High 1/20 9. Very Remote
safety/regulations 10. Hazardous w/o warning 10. Very High >1/10 10. Almost Impossible
 Page 15 of 76

AIAG Fourth Edition http://www.aiag.org/

FMEA Number Insert FMEA#
Page 1 of 1
Prepared by: Name/contact info
FMEA Date: 7/15/2008

Action Results

Occurrence
Detection
Severity
R. Responsibility & R.
Recommended Actions Taken &
P. Target Completion P.
N. Action(s) Completion Date N.
Date

Design actions to Name of Actions and

reduce severity, organization or actual completion
occurrence and individual and date
detection ratings. target completion
Severity of 9 or date
10 requires
special attention.

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 0
0 0
0 0
0 0
0 0
 Page 16 of 76

AIAG Fourth Edition http://www.aiag.org/

FMEA Number Insert FMEA#
Page 1 of 1
Prepared by: Name/contact info
FMEA Date: 7/15/2008

Action Results

Occurrence
Detection
Severity
R. Responsibility & R.
Recommended Actions Taken &
P. Target Completion P.
N. Action(s) Completion Date N.
Date

0 0
0 0
0 0
0 0
0 0
0 0
Stakeholder Effects of Failure Severity
Consumer Owner Safety Problem 10
(e.g., buyer) Major Owner Dissatisfaction 8
Moderate Owner Dissatisfaction 6
Minor Owner Dissatisfaction 4
Customer Plant Safety Problem 10
(Manufacturer) Possible Recall 9
Line Stoppage 8
Warranty Costs 7
AIAG PPAP 4th Scrap 7
Regulatory Penalty 7
Moderate Rework (<25%) 5
Plant Dissatisfaction 4
Minor Rework (<10%) 3
 Potential Page 17 of 76
Failure Mode and Effects Analysis
http://www.qimacros.com/free-lean-six-sigma-tips/fmea.html (Design FMEA)
System: Name/number of system
Subsystem Name/number of subsystem Design
Component Name/number of component Responsibility: Name
Model Years: model years/programs Key Date: 7/15/2008 7/15/08 Rev
Core Team: Team members
Current Detection
Item/Part Design Controls

Occurrence
Potential

Severity
Potential Current Design

Class
Potential Failure Cause(s) /
Requirements Effect(s) of Controls Cause
Mode Mechanism(s) of
Failure Prevention
Failure
Function
Name, Part Requirements of Manner in which Effects of failure List every List prevention List Causes
Number, or function being system/subsystem as perceived by potential cause activities to
Class analyzed /component could customers. and/or failure assure design
fail: cracked, Consequences mechanism: adequacy and
Function loosened, on other incorrect material, prevent or
deformed, leaking, systems, parts, improper reduce
oxidized, etc. or people: noise, maintenance, occurrence.
inoperative, fatigue, wear, etc.
impaired, etc.
 Page 18 of 76

Potential
Failure Mode and Effects Analysis
http://www.qimacros.com/free-lean-six-sigma-tips/fmea.html (Design FMEA)
System: Name/number of system
Subsystem Name/number of subsystem Design
Component Name/number of component Responsibility: Name
Model Years: model years/programs Key Date: 7/15/2008 7/15/08 Rev
Core Team: Team members
Current Detection
Item/Part Design Controls

Occurrence
Potential

Severity
Potential Current Design

Class
Potential Failure Cause(s) /
Requirements Effect(s) of Controls Cause
Mode Mechanism(s) of
Failure Prevention
Failure
Function

Severity of Effect: Occurrence Rating

No Effect 1. None 1. Very low <.01/1000
2. Very Minor 2. Low - 1/1000000
Annoyance 3. Minor 3. Low - 1/100000
4. Very Low 4. Moderate - 1/10000
Loss or degradation 5. Low 5. Moderate - 1/2000
of secondary function6. Moderate 6. Moderate - 1/500
Loss or degradation 7. High 7. High - 1/100
of primary function 8. Very High 8. High - 1/50
Failure to meet 9. Hazardous with warning 9. Very High 1/20
safety/regulations 10. Hazardous w/o warning 10. Very High >1/10
 Potential Page 19 of 76
re Mode and Effects Analysis
(Design FMEA) AIAG Fourth Edition http://www.aiag.org/
FMEA Number Insert FMEA#
Page 1 of 1
Prepared by: Name/contact info
FMEA Date: 7/15/2008

Current Detection
Design Controls Action Results

Occurrence
Detection

Detection
Severity
R. Responsibility & R.
Recommended Actions Taken &
Failure Mode P. Target Completion P.
N. Action(s) Completion Date N.
Date

List detection Design actions to Name of Actions and

activities to reduce severity, organization or actual completion
assure design occurrence and individual and date
adequacy and detection ratings. target completion
prevent or Severity of 9 or date
reduce 10 requires
occurrence. special attention.

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 0
0 0
0 0
0 0
 Page 20 of 76

Potential
re Mode and Effects Analysis
(Design FMEA) AIAG Fourth Edition http://www.aiag.org/
FMEA Number Insert FMEA#
Page 1 of 1
Prepared by: Name/contact info
FMEA Date: 7/15/2008

Current Detection
Design Controls Action Results

Occurrence
Detection

Detection
Severity
R. Responsibility & R.
Recommended Actions Taken &
Failure Mode P. Target Completion P.
N. Action(s) Completion Date N.
Date

0 0
0 0
0 0
0 0
0 0
0 0
0 0
Detection: Stakeholder Effects of Failure Severity
1. Almost Certain Consumer Owner Safety Problem 10
2. Very High (e.g., buyer) Major Owner Dissatisfaction 8
3. High Moderate Owner Dissatisfaction 6
4. Moderate High Minor Owner Dissatisfaction 4
5. Moderate Customer Plant Safety Problem 10
6. Low (Manufacturer) Possible Recall 9
7. Very Low Line Stoppage 8
8. Remote Warranty Costs 7
9. Very Remote AIAG PPAP 4th Scrap 7
10. Almost Impossible Regulatory Penalty 7
Moderate Rework (<25%) 5
Plant Dissatisfaction 4
Minor Rework (<10%) 3
 Potential Page 21 of 76
Failure Mode and Effects Analysis
http://www.qimacros.com/free-lean-six-sigma-tips/fmea.html (Design FMEA)
System: Name/number of system
Subsystem Name/number of subsystem Design
Component Name/number of component Responsibility: Name
Model: model years/programs Key Date: 7/15/2008
Core Team: Team members
Item/Part

Occurrence
Potential

Severity
Current Design

Class
Potential Effect(s) Cause(s) /
Requirements Potential Failure Mode Controls
of Failure Mechanism(s) of
Prevention
Failure
Function
Name, Part Requirements Manner in which part could Consequences on List every List prevention
Number, or of function fail: cracked, loosened, other systems, potential cause activities to
Class being analyzed deformed, leaking, oxidized, parts, or people: and/or failure assure design
etc. noise, unstable, mechanism: adequacy and
Function inoperative, incorrect material, prevent or
impaired, etc. improper reduce
maintenance, occurrence.
fatigue, wear, etc.
 Page 22 of 76

Potential
Failure Mode and Effects Analysis
http://www.qimacros.com/free-lean-six-sigma-tips/fmea.html (Design FMEA)
System: Name/number of system
Subsystem Name/number of subsystem Design
Component Name/number of component Responsibility: Name
Model: model years/programs Key Date: 7/15/2008
Core Team: Team members
Item/Part

Occurrence
Potential

Severity
Current Design

Class
Potential Effect(s) Cause(s) /
Requirements Potential Failure Mode Controls
of Failure Mechanism(s) of
Prevention
Failure
Function

Severity of Effect: Occurrence Rating

No Effect
Annoyance
Loss or degradation
of secondary function
Loss or degradation
of primary function
Failure to meet
safety/regulations
1. None 1. Very low <.01/1000
2. Very Minor 2. Low - 1/1000000
3. Minor 3. Low - 1/100000
4. Very Low 4. Moderate - 1/10000
5. Low 5. Moderate - 1/2000
6. Moderate 6. Moderate - 1/500
7. High 7. High - 1/100
8. Very High 8. High - 1/50
9. Hazardous with warning 9. Very High 1/20
10. Hazardous w/o warning 10. Very High >1/10
 Potential Page 23 of 76
ailure Mode and Effects Analysis
(Design FMEA) AIAG Fourth Edition http://www.aiag.org/
FMEA Number Insert FMEA#
Page 1 of 1
Prepared by: Name/contact info
FMEA Date: 7/15/2008

Action Results

Occurrence
Detection

Detection
Responsibility

Severity
Current Design R. R.
Recommended & Target Effective
Controls P. Actions Taken P.
N. Action(s) Completion Date N.
Detection
Date

List detection Design actions to Name of Actions Effective

activities to reduce severity, organization date
assure design occurrence and or individual
adequacy and detection ratings. and target
prevent or Severity of 9 or completion
reduce 10 requires date
occurrence. special attention.

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 0
0 0
0 0
0 0
0 0
0 0
0 0
 Page 24 of 76

Potential
ailure Mode and Effects Analysis
(Design FMEA) AIAG Fourth Edition http://www.aiag.org/
FMEA Number Insert FMEA#
Page 1 of 1
Prepared by: Name/contact info
FMEA Date: 7/15/2008

Action Results

Occurrence
Detection

Detection
Responsibility

Severity
Current Design R. R.
Recommended & Target Effective
Controls P. Actions Taken P.
N. Action(s) Completion Date N.
Detection
Date

0 0
0 0
0 0
0 0
Detection: Stakeholder Effects of Failure Severity
1. Almost Certain Consumer Owner Safety Problem 10
2. Very High (e.g., buyer) Major Owner Dissatisfaction 8
3. High Moderate Owner Dissatisfaction 6
4. Moderate High Minor Owner Dissatisfaction 4
5. Moderate Customer Plant Safety Problem 10
6. Low (Manufacturer) Possible Recall 9
7. Very Low Line Stoppage 8
8. Remote Warranty Costs 7
9. Very Remote AIAG PPAP 4th Scrap 7
10. Almost Impossible Regulatory Penalty 7
Moderate Rework (<25%) 5
Plant Dissatisfaction 4
Minor Rework (<10%) 3
 A-1 DESIGN FMEA CHECKLIST
Customer or Internal Part No. Revision Level
Question Yes No N/A Comment / Action Required

Was the DFMEA prepared using the Chrysler, Ford,

and General Motors Potential Failure Mode and
Effects Analysis (FMEA) reference manual, and
1 applicable customer specific requirements?
Have historical campaign and warranty data been
2 reviewed?
Have best practices and lessons learned from similar
3 part DFMEAs been considered?

4 Does the DFMEA identify Special Characteristics?

Have pass-through characteristics (glossary) been
identified and reviewed with affected suppliers for
FMEA alignment and appropriate controls in the
5 supply base?

Have special characteristics designated by the

customer or organization been reviewed with affected
6 suppliers to assure FMEA alignment?
Have design characteristics that affect high risk
7 priority failure modes been identified?
Have appropriate corrective actions been assigned to
8 high risk priority numbers?
Have appropriate corrective actions been assigned to
9 high severity numbers?

Have risk priorities been revised when corrective

10 actions have been completed and verified?

Revision Date

Prepared by:
 Person
Due Date
Responsible
Instructions
While there were originally only two forms of FMEA--design and process,
AIAG 4th has many versions of both form and SAE J1739 adds FMEAs for Machinery

1. Pick the right form (design or process) and type (A-H, simplest to most detailed).
2. For each part or process, work through each column of the form to identify failure modes and effects.

Design FMEAs
DFMEA Checklist
A. Basic Form with minimal information (SAE J1739)
B. Adds Requirements column
C. Form A with Prevention controls to left of Occurrence column
D. Form B with Prevention controls to left of Occurrence column
E. Form D with separate columns for cause/failure mode in Detection Design Controls
F. Form B with separate columns for Responsibility, Target Completion Date, Actions Taken and Completion date

Process FMEAs
PFMEA Checklist
A. Basic Form with minimal information (SAE J1739)
B. Adds Requirements column
C. Form A with Prevention controls to left of Occurrence column
D. Form B with Prevention controls to left of Occurrence column
E. Form D with separate columns for cause/failure mode in Detection Design Controls
F. Form B with separate columns for Responsibility, Target Completion Date, Actions Taken and Completion date
G. Form B with ID, Product and Process within a bridged Requirements Column
H. Form D and G combined.

Machinery FMEAs (SAE J1739 Aug 2002)

A. Basic Form - Two columns for machinery and design controls
B. Basic Form - One columns for combined machinery and design controls
© 2010 KnowWare International Inc
2253 S Oneida St Ste 3D
Denver, CO 80224

The copyright for this template is owned by KnowWare International Inc.

Licensed users:
May update this file
May copy this file
May share completed files with co-workers, suppliers and customers

Unlicensed users:
May receive and review completed templates created by licensed users
May NOT use this template to perform their own analysis without a license

To purchase a license:
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Call 888 468 1537
Fax a PO to 888 468 1536
 A-7 PROCESS FMEA CHECKLIST
Customer or Internal Part No. Revision Level
Question Yes No N/A Comment / Action Required

Was the Process FMEA prepared by a cross

functional team? Has the team taken into
account all customer specific requirements,
including FMEA methodologies as shown in the
1 current edition of FMEA?
Have all operations including subcontracted or
2 outsourced processes and services been
2 considered?

Have all operations affecting customer

requirements including fit, function, durability,
governmental regulations and safety been
3 identified and listed sequentially?

4 Were similar part/process FMEAs considered?

Have historical campaign and warranty data
5 been reviewed and used in the analysis?

Have you applied the appropriate controls to

address all of the identified failure modes? -—
Were severity, detection and occurrence
revised when corrective action was completed?
Do the effects consider the customer in terms
6 of the subsequent operation, assembly, and

Were severity, detection and occurrence

7 revised when corrective action was completed?
Do the effects consider the customer in terms
of the subsequent operation, assembly, and
8 product?
 Were customer plant problems used as an aid
9 in developing the PFMEA?

Have the causes been described in terms of

10 something that can be corrected or controlled?
Have provisions been made to control the
cause 11 of the failure mode prior to
11 subsequent or the next operation?

Revision Date

Prepared by:
 Person
Due Date
Responsible
 Potential Page 33 of 76
Failure Mode and Effects Analysis
http://www.qimacros.com/free-lean-six-sigma-tips/fmea.html (Process FMEA)

Process
Item Name/number of item Responsibility: Name
Model Years: model years/programs Key Date: 7/15/2008
Core Team: Team members
Process Step

Occurrence

Detection
Potential

Severity
Current Process Current Process R.

Class
Potential Effect(s) Cause(s) /
Potential Failure Mode Controls Controls P.
of Failure Mechanism(s) of N.
Prevention Detection
Failure
Requirements
Name, Part Manner in which part could Consequences on List every List prevention List detection
Number, or fail: cracked, loosened, other systems, potential cause activities to activities to
Class deformed, leaking, oxidized, parts, or people: and/or failure assure process assure process
etc. noise, unstable, mechanism: adequacy and adequacy and
Function inoperative, incorrect material, prevent or prevent or
impaired, etc. improper reduce reduce
maintenance, occurrence. occurrence.
fatigue, wear, etc.
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
 Page 34 of 76

Potential
Failure Mode and Effects Analysis
http://www.qimacros.com/free-lean-six-sigma-tips/fmea.html (Process FMEA)

Process
Item Name/number of item Responsibility: Name
Model Years: model years/programs Key Date: 7/15/2008
Core Team: Team members
Process Step

Occurrence

Detection
Potential

Severity
Current Process Current Process R.

Class
Potential Effect(s) Cause(s) /
Potential Failure Mode Controls Controls P.
of Failure Mechanism(s) of N.
Prevention Detection
Failure
Requirements
0
0
0
0
Severity of Effect: Occurrence Rating Detection:
No Effect 1. None 1. Very low <.01/1000 1. Almost Certain
2. Very Minor 2. Low - 1/1000000 2. Very High
Annoyance 3. Minor 3. Low - 1/100000 3. High
4. Very Low 4. Moderate - 1/10000 4. Moderate High
Loss or degradation 5. Low 5. Moderate - 1/2000 5. Moderate
of secondary function 6. Moderate 6. Moderate - 1/500 6. Low
Loss or degradation 7. High 7. High - 1/100 7. Very Low
of primary function 8. Very High 8. High - 1/50 8. Remote
Failure to meet 9. Hazardous with warning 9. Very High 1/20 9. Very Remote
safety/regulations 10. Hazardous w/o warning 10. Very High >1/10 10. Almost Impossible
 Page 35 of 76

AIAG Fourth Edition http://www.aiag.org/ SAE J1739

FMEA Number Insert FMEA#
Page 1 of 1
Prepared by: who
FMEA Date: 7/15/2008

Action Results

Occurrence
Detection
Severity
Responsibility & R.
Recommended Actions Taken &
Target Completion P.
Action(s) Completion Date N.
Date

Design actions to Name of Actions and

reduce severity, organization or actual completion
occurrence and individual and date
detection ratings. target completion
Severity of 9 or date
10 requires
special attention.

0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
 Page 36 of 76

AIAG Fourth Edition http://www.aiag.org/ SAE J1739

FMEA Number Insert FMEA#
Page 1 of 1
Prepared by: who
FMEA Date: 7/15/2008

Action Results

Occurrence
Detection
Severity
Responsibility & R.
Recommended Actions Taken &
Target Completion P.
Action(s) Completion Date N.
Date

0
0
0
0
Stakeholder Effects of Failure Severity
Consumer Owner Safety Problem 10
(e.g., buyer) Major Owner Dissatisfaction 8
Moderate Owner Dissatisfaction 6
Minor Owner Dissatisfaction 4
Customer Plant Safety Problem 10
(Manufacturer) Possible Recall 9
Line Stoppage 8
Warranty Costs 7
AIAG PPAP 4th Scrap 7
Regulatory Penalty 7
Moderate Rework (<25%) 5
Plant Dissatisfaction 4
Minor Rework (<10%) 3
 Potential Page 37 of 76
Failure Mode and Effects Analysis
http://www.qimacros.com/free-lean-six-sigma-tips/fmea.html (Process FMEA)

Process
Item Name/number of item Responsibility: Name
Model Years: model years/programs Key Date: 7/15/2008
Core Team: Team members
Process Step

Occurrence
Potential

Severity
Current Process

Class
Potential Effect(s) Cause(s) /
Requirements Potential Failure Mode Controls
of Failure Mechanism(s) of
Prevention
Failure
Function
Name, Part Requirements Manner in which part could Consequences on List every List prevention
Number, or of function fail: cracked, loosened, other systems, potential cause activities to
Class being analyzed deformed, leaking, oxidized, parts, or people: and/or failure assure process
etc. noise, unstable, mechanism: adequacy and
Function inoperative, incorrect material, prevent or
impaired, etc. improper reduce
maintenance, occurrence.
fatigue, wear, etc.
 Page 38 of 76

Potential
Failure Mode and Effects Analysis
http://www.qimacros.com/free-lean-six-sigma-tips/fmea.html (Process FMEA)

Process
Item Name/number of item Responsibility: Name
Model Years: model years/programs Key Date: 7/15/2008
Core Team: Team members
Process Step

Occurrence
Potential

Severity
Current Process

Class
Potential Effect(s) Cause(s) /
Requirements Potential Failure Mode Controls
of Failure Mechanism(s) of
Prevention
Failure
Function

Severity of Effect: Occurrence Rating

No Effect
Annoyance
Loss or degradation
of secondary function
Loss or degradation
of primary function
Failure to meet
safety/regulations
1. None 1. Very low <.01/1000
2. Very Minor 2. Low - 1/1000000
3. Minor 3. Low - 1/100000
4. Very Low 4. Moderate - 1/10000
5. Low 5. Moderate - 1/2000
6. Moderate 6. Moderate - 1/500
7. High 7. High - 1/100
8. Very High 8. High - 1/50
9. Hazardous with warning 9. Very High 1/20
10. Hazardous w/o warning 10. Very High >1/10
 Potential Page 39 of 76
Failure Mode and Effects Analysis
(Process FMEA) AIAG Fourth Edition http://www.aiag.org/
FMEA Number Insert FMEA#
Page 1 of 1
Prepared by: who
FMEA Date: 7/15/2008

Action Results

Occurrence
Detection

Detection
Severity
Current Process R. Responsibility & R.
Recommended Actions Taken &
Controls P. Target Completion P.
N. Action(s) Completion Date N.
Detection Date

List detection Design actions to Name of Actions and

activities to reduce severity, organization or actual completion
assure process occurrence and individual and date
adequacy and detection ratings. target completion
prevent or Severity of 9 or date
reduce 10 requires
occurrence. special attention.

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 0
0 0
0 0
0 0
0 0
0 0
0 0
 Page 40 of 76

Potential
Failure Mode and Effects Analysis
(Process FMEA) AIAG Fourth Edition http://www.aiag.org/
FMEA Number Insert FMEA#
Page 1 of 1
Prepared by: who
FMEA Date: 7/15/2008

Action Results

Occurrence
Detection

Detection
Severity
Current Process R. Responsibility & R.
Recommended Actions Taken &
Controls P. Target Completion P.
N. Action(s) Completion Date N.
Detection Date

0 0
0 0
0 0
0 0
Detection: Stakeholder Effects of Failure Severity
1. Almost Certain Consumer Owner Safety Problem 10
2. Very High (e.g., buyer) Major Owner Dissatisfaction 8
3. High Moderate Owner Dissatisfaction 6
4. Moderate High Minor Owner Dissatisfaction 4
5. Moderate Customer Plant Safety Problem 10
6. Low (Manufacturer) Possible Recall 9
7. Very Low Line Stoppage 8
8. Remote Warranty Costs 7
9. Very Remote AIAG PPAP 4th Scrap 7
10. Almost Impossible Regulatory Penalty 7
Moderate Rework (<25%) 5
Plant Dissatisfaction 4
Minor Rework (<10%) 3
 Potential Page 41 of 76
Failure Mode and Effects Analysis
http://www.qimacros.com/free-lean-six-sigma-tips/fmea.html (Process FMEA)

Process
Item Name/number of item Responsibility: Name
Model Years: model years/programs Key Date: 7/15/2008
Core Team: Team members
Process Step

Occurrence

Detection
Potential

Severity
Current Process Current Process R.

Class
Potential Effect(s) Cause(s) /
Potential Failure Mode Controls Controls P.
of Failure Mechanism(s) of N.
Prevention Detection
Failure
Requirements
Name, Part Manner in which part could Consequences on List every List prevention List detection
Number, or fail: cracked, loosened, other systems, potential cause activities to activities to
Class deformed, leaking, oxidized, parts, or people: and/or failure assure process assure process
etc. noise, unstable, mechanism: adequacy and adequacy and
Function inoperative, incorrect material, prevent or prevent or
impaired, etc. improper reduce reduce
maintenance, occurrence. occurrence.
fatigue, wear, etc.
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
 Page 42 of 76

Potential
Failure Mode and Effects Analysis
http://www.qimacros.com/free-lean-six-sigma-tips/fmea.html (Process FMEA)

Process
Item Name/number of item Responsibility: Name
Model Years: model years/programs Key Date: 7/15/2008
Core Team: Team members
Process Step

Occurrence

Detection
Potential

Severity
Current Process Current Process R.

Class
Potential Effect(s) Cause(s) /
Potential Failure Mode Controls Controls P.
of Failure Mechanism(s) of N.
Prevention Detection
Failure
Requirements
0
0
0
0
Severity of Effect: Occurrence Rating Detection:
No Effect 1. None 1. Very low <.01/1000 1. Almost Certain
2. Very Minor 2. Low - 1/1000000 2. Very High
Annoyance 3. Minor 3. Low - 1/100000 3. High
4. Very Low 4. Moderate - 1/10000 4. Moderate High
Loss or degradation 5. Low 5. Moderate - 1/2000 5. Moderate
of secondary function 6. Moderate 6. Moderate - 1/500 6. Low
Loss or degradation 7. High 7. High - 1/100 7. Very Low
of primary function 8. Very High 8. High - 1/50 8. Remote
Failure to meet 9. Hazardous with warning 9. Very High 1/20 9. Very Remote
safety/regulations 10. Hazardous w/o warning 10. Very High >1/10 10. Almost Impossible
 Page 43 of 76

AIAG Fourth Edition http://www.aiag.org/

FMEA Number Insert FMEA#
Page 1 of 1
Prepared by: who
FMEA Date: 7/15/2008

Action Results

Occurrence
Detection
Severity
Responsibility & R.
Recommended Actions Taken &
Target Completion P.
Action(s) Completion Date N.
Date

Design actions to Name of Actions and

reduce severity, organization or actual completion
occurrence and individual and date
detection ratings. target completion
Severity of 9 or date
10 requires
special attention.

0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
 Page 44 of 76

AIAG Fourth Edition http://www.aiag.org/

FMEA Number Insert FMEA#
Page 1 of 1
Prepared by: who
FMEA Date: 7/15/2008

Action Results

Occurrence
Detection
Severity
Responsibility & R.
Recommended Actions Taken &
Target Completion P.
Action(s) Completion Date N.
Date

0
0
0
0
Stakeholder Effects of Failure Severity
Consumer Owner Safety Problem 10
(e.g., buyer) Major Owner Dissatisfaction 8
Moderate Owner Dissatisfaction 6
Minor Owner Dissatisfaction 4
Customer Plant Safety Problem 10
(Manufacturer) Possible Recall 9
Line Stoppage 8
Warranty Costs 7
AIAG PPAP 4th Scrap 7
Regulatory Penalty 7
Moderate Rework (<25%) 5
Plant Dissatisfaction 4
Minor Rework (<10%) 3
 Potential Page 45 of 76
Failure Mode and Effects Analysis
http://www.qimacros.com/free-lean-six-sigma-tips/fmea.html (Process FMEA)

Process
Item Name/number of item Responsibility: Name
Model Years: model years/programs Key Date: 7/15/2008 7/15/08 Rev
Core Team: Team members
Process Step Current Design

Occurrence

Detection
Potential

Severity
Potential Current Process Current Process

Class
Potential Failure Cause(s) /
Requirements Effect(s) of Controls Controls
Mode Mechanism(s) of
Failure Prevention Detection
Failure
Function
Name, Part Requirements of Manner in which Effects of failure List every List prevention List detection
Number, or function being system/subsystem as perceived by potential cause activities to activities to
Class analyzed /component could customers. and/or failure assure process assure process
fail: cracked, Consequences mechanism: adequacy and adequacy and
Function loosened, on other incorrect material, prevent or prevent or
deformed, leaking, systems, parts, improper reduce reduce
oxidized, etc. or people: noise, maintenance, occurrence. occurrence.
inoperative, fatigue, wear, etc.
impaired, etc.
 Page 46 of 76

Potential
Failure Mode and Effects Analysis
http://www.qimacros.com/free-lean-six-sigma-tips/fmea.html (Process FMEA)

Process
Item Name/number of item Responsibility: Name
Model Years: model years/programs Key Date: 7/15/2008 7/15/08 Rev
Core Team: Team members
Process Step Current Design

Occurrence

Detection
Potential

Severity
Potential Current Process Current Process

Class
Potential Failure Cause(s) /
Requirements Effect(s) of Controls Controls
Mode Mechanism(s) of
Failure Prevention Detection
Failure
Function

Severity of Effect: Occurrence Rating Detection:

No Effect 1. None 1. Very low <.01/1000 1. Almost Certain
2. Very Minor 2. Low - 1/1000000 2. Very High
Annoyance 3. Minor 3. Low - 1/100000 3. High
4. Very Low 4. Moderate - 1/10000 4. Moderate High
Loss or degradation 5. Low 5. Moderate - 1/2000 5. Moderate
of secondary function6. Moderate 6. Moderate - 1/500 6. Low
Loss or degradation 7. High 7. High - 1/100 7. Very Low
of primary function 8. Very High 8. High - 1/50 8. Remote
Failure to meet 9. Hazardous with warning 9. Very High 1/20 9. Very Remote
safety/regulations 10. Hazardous w/o warning 10. Very High >1/10 10. Almost Impossible
 Page 47 of 76

AIAG Fourth Edition http://www.aiag.org/

FMEA Number Insert FMEA#
Page 1 of 1
Prepared by: Name/contact info
FMEA Date: 7/15/2008

Action Results

Occurrence
Detection
Severity
R. Responsibility & R.
Recommended Actions Taken &
P. Target Completion P.
N. Action(s) Completion Date N.
Date

Design actions to Name of Actions and

reduce severity, organization or actual completion
occurrence and individual and date
detection ratings. target completion
Severity of 9 or date
10 requires
special attention.

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 0
0 0
0 0
0 0
0 0
 Page 48 of 76

AIAG Fourth Edition http://www.aiag.org/

FMEA Number Insert FMEA#
Page 1 of 1
Prepared by: Name/contact info
FMEA Date: 7/15/2008

Action Results

Occurrence
Detection
Severity
R. Responsibility & R.
Recommended Actions Taken &
P. Target Completion P.
N. Action(s) Completion Date N.
Date

0 0
0 0
0 0
0 0
0 0
0 0
Stakeholder Effects of Failure Severity
Consumer Owner Safety Problem 10
(e.g., buyer) Major Owner Dissatisfaction 8
Moderate Owner Dissatisfaction 6
Minor Owner Dissatisfaction 4
Customer Plant Safety Problem 10
(Manufacturer) Possible Recall 9
Line Stoppage 8
Warranty Costs 7
AIAG PPAP 4th Scrap 7
Regulatory Penalty 7
Moderate Rework (<25%) 5
Plant Dissatisfaction 4
Minor Rework (<10%) 3
 Page 49 of 76
Potential
Failure Mode and Effects Analysis
http://www.qimacros.com/free-lean-six-sigma-tips/fmea.html (Process FMEA)

Process
Item Name/number of item Responsibility: Name
Model Years: model years/programs Key Date: 7/15/2008 7/15/08 Rev
Core Team: Team members
Current Detection
Process Step Process Controls

Occurrence
Potential

Severity
Potential Current Process

Class
Potential Failure Cause(s) /
Requirements Effect(s) of Controls Cause
Mode Mechanism(s) of
Failure Prevention
Failure
Function
Name, Part Requirements of Manner in which Effects of failure List every List prevention List Causes
Number, or function being system/subsystem as perceived by potential cause activities to
Class analyzed /component could customers. and/or failure assure design
fail: cracked, Consequences mechanism: adequacy and
Function loosened, on other incorrect material, prevent or
deformed, leaking, systems, parts, improper reduce
oxidized, etc. or people: noise, maintenance, occurrence.
inoperative, fatigue, wear, etc.
impaired, etc.
 Page 50 of 76

Potential
Failure Mode and Effects Analysis
http://www.qimacros.com/free-lean-six-sigma-tips/fmea.html (Process FMEA)

Process
Item Name/number of item Responsibility: Name
Model Years: model years/programs Key Date: 7/15/2008 7/15/08 Rev
Core Team: Team members
Current Detection
Process Step Process Controls

Occurrence
Potential

Severity
Potential Current Process

Class
Potential Failure Cause(s) /
Requirements Effect(s) of Controls Cause
Mode Mechanism(s) of
Failure Prevention
Failure
Function

Severity of Effect: Occurrence Rating

No Effect 1. None 1. Very low <.01/1000
2. Very Minor 2. Low - 1/1000000
Annoyance 3. Minor 3. Low - 1/100000
4. Very Low 4. Moderate - 1/10000
Loss or degradation 5. Low 5. Moderate - 1/2000
of secondary function6. Moderate 6. Moderate - 1/500
Loss or degradation 7. High 7. High - 1/100
of primary function 8. Very High 8. High - 1/50
Failure to meet 9. Hazardous with warning 9. Very High 1/20
safety/regulations 10. Hazardous w/o warning 10. Very High >1/10
 Page 51 of 76
Potential
re Mode and Effects Analysis
(Process FMEA) AIAG Fourth Edition http://www.aiag.org/
FMEA Number Insert FMEA#
Page 1 of 1
Prepared by: Name/contact info
FMEA Date: 7/15/2008

Current Detection
Process Controls Action Results

Occurrence
Detection

Detection
Severity
R. Responsibility & R.
Recommended Actions Taken &
Failure Mode P. Target Completion P.
N. Action(s) Completion Date N.
Date

List detection Design actions to Name of Actions and

activities to reduce severity, organization or actual completion
assure design occurrence and individual and date
adequacy and detection ratings. target completion
prevent or Severity of 9 or date
reduce 10 requires
occurrence. special attention.

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 0
0 0
0 0
 Page 52 of 76

Potential
re Mode and Effects Analysis
(Process FMEA) AIAG Fourth Edition http://www.aiag.org/
FMEA Number Insert FMEA#
Page 1 of 1
Prepared by: Name/contact info
FMEA Date: 7/15/2008

Current Detection
Process Controls Action Results

Occurrence
Detection

Detection
Severity
R. Responsibility & R.
Recommended Actions Taken &
Failure Mode P. Target Completion P.
N. Action(s) Completion Date N.
Date

0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
Detection: Stakeholder Effects of Failure Severity
1. Almost Certain Consumer Owner Safety Problem 10
2. Very High (e.g., buyer) Major Owner Dissatisfaction 8
3. High Moderate Owner Dissatisfaction 6
4. Moderate High Minor Owner Dissatisfaction 4
5. Moderate Customer Plant Safety Problem 10
6. Low (Manufacturer) Possible Recall 9
7. Very Low Line Stoppage 8
8. Remote Warranty Costs 7
9. Very Remote AIAG PPAP 4th Scrap 7
10. Almost Impossible Regulatory Penalty 7
Moderate Rework (<25%) 5
Plant Dissatisfaction 4
Minor Rework (<10%) 3
 Potential Page 53 of 76
Failure Mode and Effects Analysis
http://www.qimacros.com/free-lean-six-sigma-tips/fmea.html (Process FMEA)

Process
Item Name/number of item Responsibility: Name
Model Years: model years/programs Key Date: 7/15/2008
Core Team: Team members
Process Step

Occurrence
Potential

Severity
Current Process

Class
Potential Effect(s) Cause(s) /
Requirements Potential Failure Mode Controls
of Failure Mechanism(s) of
Prevention
Failure
Function
Name, Part Requirements Manner in which part could Consequences on List every List prevention
Number, or of function fail: cracked, loosened, other systems, potential cause activities to
Class being analyzed deformed, leaking, oxidized, parts, or people: and/or failure assure process
etc. noise, unstable, mechanism: adequacy and
Function inoperative, incorrect material, prevent or
impaired, etc. improper reduce
maintenance, occurrence.
fatigue, wear, etc.
 Page 54 of 76

Potential
Failure Mode and Effects Analysis
http://www.qimacros.com/free-lean-six-sigma-tips/fmea.html (Process FMEA)

Process
Item Name/number of item Responsibility: Name
Model Years: model years/programs Key Date: 7/15/2008
Core Team: Team members
Process Step

Occurrence
Potential

Severity
Current Process

Class
Potential Effect(s) Cause(s) /
Requirements Potential Failure Mode Controls
of Failure Mechanism(s) of
Prevention
Failure
Function

Severity of Effect: Occurrence Rating

No Effect
Annoyance
Loss or degradation
of secondary function
Loss or degradation
of primary function
Failure to meet
safety/regulations
1. None 1. Very low <.01/1000
2. Very Minor 2. Low - 1/1000000
3. Minor 3. Low - 1/100000
4. Very Low 4. Moderate - 1/10000
5. Low 5. Moderate - 1/2000
6. Moderate 6. Moderate - 1/500
7. High 7. High - 1/100
8. Very High 8. High - 1/50
9. Hazardous with warning 9. Very High 1/20
10. Hazardous w/o warning 10. Very High >1/10
 Potential Page 55 of 76
ailure Mode and Effects Analysis
(Process FMEA) AIAG Fourth Edition http://www.aiag.org/
FMEA Number Insert FMEA#
Page 1 of 1
Prepared by: Name/contact info
FMEA Date: 7/15/2008

Action Results

Occurrence
Detection

Detection
Responsibility

Severity
Current Process R. R.
Recommended & Target Effective
Controls P. Actions Taken P.
N. Action(s) Completion Date N.
Detection
Date

List detection Design actions to Name of Actions Effective

activities to reduce severity, organization date
assure process occurrence and or individual
adequacy and detection ratings. and target
prevent or Severity of 9 or completion
reduce 10 requires date
occurrence. special attention.

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 0
0 0
0 0
0 0
0 0
0 0
0 0
 Page 56 of 76

Potential
ailure Mode and Effects Analysis
(Process FMEA) AIAG Fourth Edition http://www.aiag.org/
FMEA Number Insert FMEA#
Page 1 of 1
Prepared by: Name/contact info
FMEA Date: 7/15/2008

Action Results

Occurrence
Detection

Detection
Responsibility

Severity
Current Process R. R.
Recommended & Target Effective
Controls P. Actions Taken P.
N. Action(s) Completion Date N.
Detection
Date

0 0
0 0
0 0
0 0
Detection: Stakeholder Effects of Failure Severity
1. Almost Certain Consumer Owner Safety Problem 10
2. Very High (e.g., buyer) Major Owner Dissatisfaction 8
3. High Moderate Owner Dissatisfaction 6
4. Moderate High Minor Owner Dissatisfaction 4
5. Moderate Customer Plant Safety Problem 10
6. Low (Manufacturer) Possible Recalll 9
7. Very Low Line Stoppage 8
8. Remote Warranty Costs 7
9. Very Remote AIAG PPAP 4th Scrap 7
10. Almost Impossible Regulatory Penalty 7
Moderate Rework (<25%) 5
Plant Dissatisfaction 4
Minor Rework (<10%) 3
 Page 57 of 76
Potential
Failure Mode and Effects Analysis
http://www.qimacros.com/free-lean-six-sigma-tips/fmea.html (Process FMEA)

Process
Item Name/number of item Responsibility: Name
Model Years: model years/programs Key Date: 7/15/2008
Core Team: Team members
Process Step Requirements

Occurrence
Potential

Severity
Current Process

Class
Potential Effect(s) Cause(s) /
ID Product Process Potential Failure Mode Controls
of Failure Mechanism(s) of
Prevention
Failure
Function
Name, Part Requireme Manner in which part could Consequences on List every List prevention
Number, or nts of fail: cracked, loosened, other systems, potential cause activities to
Class function deformed, leaking, oxidized, parts, or people: and/or failure assure process
being etc. noise, unstable, mechanism: adequacy and
Function analyzed inoperative, incorrect material, prevent or
impaired, etc. improper reduce
maintenance, occurrence.
fatigue, wear, etc.
 Page 58 of 76

Potential
Failure Mode and Effects Analysis
http://www.qimacros.com/free-lean-six-sigma-tips/fmea.html (Process FMEA)

Process
Item Name/number of item Responsibility: Name
Model Years: model years/programs Key Date: 7/15/2008
Core Team: Team members
Process Step Requirements

Occurrence
Potential

Severity
Current Process

Class
Potential Effect(s) Cause(s) /
ID Product Process Potential Failure Mode Controls
of Failure Mechanism(s) of
Prevention
Failure
Function

Severity of Effect: Occurrence Rating

No Effect 1. None 1. Very low <.01/1000
2. Very Minor 2. Low - 1/1000000
Annoyance 3. Minor 3. Low - 1/100000
4. Very Low 4. Moderate - 1/10000
Loss or degradation 5. Low 5. Moderate - 1/2000
of secondary function 6. Moderate 6. Moderate - 1/500
Loss or degradation 7. High 7. High - 1/100
of primary function 8. Very High 8. High - 1/50
Failure to meet 9. Hazardous with warning 9. Very High 1/20
safety/regulations 10. Hazardous w/o warning 10. Very High >1/10
 Potential Page 59 of 76
Failure Mode and Effects Analysis
(Process FMEA) AIAG Fourth Edition http://www.aiag.org/
FMEA Number Insert FMEA#
Page 1 of 1
Prepared by: who
FMEA Date: 7/15/2008

Action Results

Occurrence
Detection

Detection
Severity
Current Process R. Responsibility & R.
Recommended Actions Taken &
Controls P. Target Completion P.
N. Action(s) Completion Date N.
Detection Date

List detection Design actions to Name of Actions and

activities to reduce severity, organization or actual completion
assure process occurrence and individual and date
adequacy and detection ratings. target completion
prevent or Severity of 9 or date
reduce 10 requires
occurrence. special attention.

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 0
0 0
0 0
0 0
0 0
0 0
0 0
 Page 60 of 76

Potential
Failure Mode and Effects Analysis
(Process FMEA) AIAG Fourth Edition http://www.aiag.org/
FMEA Number Insert FMEA#
Page 1 of 1
Prepared by: who
FMEA Date: 7/15/2008

Action Results

Occurrence
Detection

Detection
Severity
Current Process R. Responsibility & R.
Recommended Actions Taken &
Controls P. Target Completion P.
N. Action(s) Completion Date N.
Detection Date

0 0
0 0
0 0
0 0
Detection: Stakeholder Effects of Failure Severity
1. Almost Certain Consumer Owner Safety Problem 10
2. Very High (e.g., buyer) Major Owner Dissatisfaction 8
3. High Moderate Owner Dissatisfaction 6
4. Moderate High Minor Owner Dissatisfaction 4
5. Moderate Customer Plant Safety Problem 10
6. Low (Manufacturer) Possible Recall 9
7. Very Low Line Stoppage 8
8. Remote Warranty Costs 7
9. Very Remote AIAG PPAP 4th Scrap 7
10. Almost Impossible Regulatory Penalty 7
Moderate Rework (<25%) 5
Plant Dissatisfaction 4
Minor Rework (<10%) 3
 PotentialPage 61 of 76
Failure Mode and Effects Analysis
http://www.qimacros.com/free-lean-six-sigma-tips/fmea.html (Process FMEA)

Process
Item Name/number of item Responsibility: Name
Model Years: model years/programs Key Date: 7/15/2008 7/15/08 Rev
Core Team: Team members
Process Step Requirements

Occurrence
Potential

Severity
Potential Current Process

Class
Potential Failure Cause(s) /
ID Product Process Effect(s) of Controls
Mode Mechanism(s) of
Failure Prevention
Failure
Function
Name, Part Requir Manner in which Effects of failure List every List prevention
Number, or ement system/subsystem as perceived by potential cause activities to
Class s of /component could customers. and/or failure assure process
functio fail: cracked, Consequences mechanism: adequacy and
Function n loosened, on other incorrect material, prevent or
being deformed, leaking, systems, parts, improper reduce
analyz oxidized, etc. or people: noise, maintenance, occurrence.
ed inoperative, fatigue, wear, etc.
impaired, etc.
 Page 62 of 76

Potential
Failure Mode and Effects Analysis
http://www.qimacros.com/free-lean-six-sigma-tips/fmea.html (Process FMEA)

Process
Item Name/number of item Responsibility: Name
Model Years: model years/programs Key Date: 7/15/2008 7/15/08 Rev
Core Team: Team members
Process Step Requirements

Occurrence
Potential

Severity
Potential Current Process

Class
Potential Failure Cause(s) /
ID Product Process Effect(s) of Controls
Mode Mechanism(s) of
Failure Prevention
Failure
Function

Severity of Effect: Occurrence Rating

No Effect 1. None 1. Very low <.01/1000
2. Very Minor 2. Low - 1/1000000
Annoyance 3. Minor 3. Low - 1/100000
4. Very Low 4. Moderate - 1/10000
Loss or degradation 5. Low 5. Moderate - 1/2000
of secondary function6. Moderate 6. Moderate - 1/500
Loss or degradation 7. High 7. High - 1/100
of primary function 8. Very High 8. High - 1/50
Failure to meet 9. Hazardous with warning 9. Very High 1/20
safety/regulations 10. Hazardous w/o warning 10. Very High >1/10
 Potential Page 63 of 76
Failure Mode and Effects Analysis
(Process FMEA) AIAG Fourth Edition http://www.aiag.org/
FMEA Number Insert FMEA#
Page 1 of 1
Prepared by: Name/contact info
FMEA Date: 7/15/2008

Action Results

Occurrence
Detection

Detection
Severity
Current Process R. Responsibility & R.
Recommended Actions Taken &
Controls P. Target Completion P.
N. Action(s) Completion Date N.
Detection Date

List detection Design actions to Name of Actions and

activities to reduce severity, organization or actual completion
assure process occurrence and individual and date
adequacy and detection ratings. target completion
prevent or Severity of 9 or date
reduce 10 requires
occurrence. special attention.

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 0
0 0
0 0
0 0
0 0
 Page 64 of 76

Potential
Failure Mode and Effects Analysis
(Process FMEA) AIAG Fourth Edition http://www.aiag.org/
FMEA Number Insert FMEA#
Page 1 of 1
Prepared by: Name/contact info
FMEA Date: 7/15/2008

Action Results

Occurrence
Detection

Detection
Severity
Current Process R. Responsibility & R.
Recommended Actions Taken &
Controls P. Target Completion P.
N. Action(s) Completion Date N.
Detection Date

0 0
0 0
0 0
0 0
0 0
0 0
Detection: Stakeholder Effects of Failure Severity
1. Almost Certain Consumer Owner Safety Problem 10
2. Very High (e.g., buyer) Major Owner Dissatisfaction 8
3. High Moderate Owner Dissatisfaction 6
4. Moderate High Minor Owner Dissatisfaction 4
5. Moderate Customer Plant Safety Problem 10
6. Low (Manufacturer) Possible Recall 9
7. Very Low Line Stoppage 8
8. Remote Warranty Costs 7
9. Very Remote AIAG PPAP 4th Scrap 7
10. Almost Impossible Regulatory Penalty 7
Moderate Rework (<25%) 5
Plant Dissatisfaction 4
Minor Rework (<10%) 3
 Potential Page 65 of 76
Failure Mode and Effects Analysis
http://www.qimacros.com/free-lean-six-sigma-tips/fmea.html (Machine FMEA)
System: Name/number of system
Subsystem Name/number of subsystem Design
Component Name/number of component Responsibility: Name
Model: model years/programs Key Date: 7/15/2008
Core Team: Team members
Item/Function

Occurrence
Potential

Severity
Class
Potential Effect(s) of Cause(s) / Current Machinery
Potential Failure Mode
Failure Mechanism(s) of Controls Prevention
Failure
Requirements
Name, Machine Manner in which machinery could Consequences on other List every List prevention
Number, or fail: bent, cracked, dirty, broken, systems, parts, or potential cause activities to assure
Class warped, binding, worn, grounded, people: and/or failure machinery adequacy
short cuircuit, open circuit. Breakdowns, degraded mechanism: tool and prevent or reduce
Function output, inadequate drift, incorrect occurrence.
Assumes: torque, intermittent material specified,
1. Incoming parts and materials operation, excessive over-stressing,
are correct. noise, excessive effort, improper
2. Machinery will be built, endangers operator, maintenance,
installed, aadjusted, and increased cycle time, improper
maintained to specifications impared performance, specification,
3. All preceding steps in the loss of production, partial contamination,
sequence of operations have or complete loss of excessive heat,
been executed to specifications. function, excessive wear.
vibration, lack of
repeatability, excessive
backlash.
 Potential Page 66 of 76
Failure Mode and Effects Analysis
http://www.qimacros.com/free-lean-six-sigma-tips/fmea.html (Machine FMEA)
System: Name/number of system
Subsystem Name/number of subsystem Design
Component Name/number of component Responsibility: Name
Model: model years/programs Key Date: 7/15/2008
Core Team: Team members
Item/Function

Occurrence
Potential

Severity
Class
Potential Effect(s) of Cause(s) / Current Machinery
Potential Failure Mode
Failure Mechanism(s) of Controls Prevention
Failure
Requirements

Severity of Effect: Occurrence Failure/cycles

No Effect 1. None 1. Very low <1/900000 R(t)=98% MTBF=50x
within spec limits 2. Very Minor 2. Low - 1/900000 R(t)=95% MTBF=20x
Downtime 0-10 min, no defects 3. Minor 3. Low - 1/540000 R(t)=90% MTBF=10x
Downtime 10-30 min, no defects 4. Very Low 4. Moderate - 1/360000 R(t)=85% MTBF=6x
Downtime 30-60 min, 1hr of defects 5. Low 5. Moderate - 1/270000 R(t)=78% MTBF=4x
Downtime and defects 1-2hrs. 6. Moderate 6. Moderate - 1/180000 R(t)=61% MTBF=2x
Downtime > 4hrs, defects 2-4 hrs 7. High 7. High - 1/90000 R(t)=37% MTBF=Spec
Downtime > 8 hrs, defects > 4 hrs 8. Very High 8. High - 1/36000 R(t)=19% MTBF=0.6x
Affects personnel 9. Hazardous with warning 9. Very High 1/900 R(t)=5% MTBF=0.3x
safety/regulations 10. Hazardous w/o warning 10. Very High >1/90 R(t)<1% MTBF=0.1x
 Potential Page 67 of 76
ailure Mode and Effects Analysis
(Machine FMEA) AIAG Fourth Edition SAE J1739 Aug2002
FMEA Number Insert FMEA#
Page 1 of 1
Prepared by: who
FMEA Date: 7/15/2008

Action Results

Occurrence
Detection

Detection
Current

Severity
R. Responsibility & R.
Machinery Recommended Actions Taken &
P. Target Completion P.
Controls N. Action(s) Completion Date N.
Date
Detection

List detection Design actions to Name of Actions and

activities to reduce severity, organization or actual completion
assure occurrence and individual and date
machinery detection ratings. target completion
adequacy and Severity of 9 or date
prevent or 10 requires
reduce special attention.
occurrence.

0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
 Potential Page 68 of 76
ailure Mode and Effects Analysis
(Machine FMEA) AIAG Fourth Edition SAE J1739 Aug2002
FMEA Number Insert FMEA#
Page 1 of 1
Prepared by: who
FMEA Date: 7/15/2008

Action Results

Occurrence
Detection

Detection
Current

Severity
R. Responsibility & R.
Machinery Recommended Actions Taken &
P. Target Completion P.
Controls N. Action(s) Completion Date N.
Date
Detection

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 0
Detection: Stakeholder Effects of Failure Severity
1. Almost Certain Consumer Owner Safety Problem 10
2. Very High (e.g., buyer) Major Owner Dissatisfaction 8
3. High Moderate Owner Dissatisfaction 6
4. Moderate High Minor Owner Dissatisfaction 4
5. Moderate Customer Plant Safety Problem 10
6. Low (Manufacturer) Possible Recall 9
7. Very Low Line Stoppage 8
8. Remote Warranty Costs 7
9. Very Remote AIAG PPAP 4th Scrap 7
10. Almost Impossible Regulatory Penalty 7
Moderate Rework (<25%) 5
Plant Dissatisfaction 4
Minor Rework (<10%) 3
 Page 69 of 76

Potential
Failure Mode and Effects Analysis
http://www.qimacros.com/free-lean-six-sigma-tips/fmea.html (Machine FMEA)
System: Name/number of system
Subsystem Name/number of subsystem Design
Component Name/number of component Responsibility: Name
Model: model years/programs Key Date: 7/15/2008
Core Team: Team members
Item/Function

Occurrence

Detection
Potential Current Machinery

Severity
Class
Potential Effect(s) of Cause(s) / Controls R. P.
Potential Failure Mode N.
Failure Mechanism(s) of -Prevention
Failure -Detection
Requirements
 Potential
Failure Mode and Effects Analysis
http://www.qimacros.com/free-lean-six-sigma-tips/fmea.html (Machine FMEA) Page 70 of 76
System: Name/number of system
Subsystem Name/number of subsystem Design
Component Name/number of component Responsibility: Name
Model: model years/programs Key Date: 7/15/2008
Core Team: Team members
Item/Function

Occurrence

Detection
Potential Current Machinery

Severity
Class
Potential Effect(s) of Cause(s) / Controls R. P.
Potential Failure Mode N.
Failure Mechanism(s) of -Prevention
Failure -Detection
Requirements
Name, Machine Manner in which machinery could Consequences on other List every List prevention and
Number, or fail: bent, cracked, dirty, broken, systems, parts, or potential cause detection activities to
Class warped, binding, worn, grounded, people: and/or failure assure machinery
short cuircuit, open circuit. Breakdowns, degraded mechanism: tool adequacy and prevent or
Function output, inadequate drift, incorrect reduce occurrence.
Assumes: torque, intermittent material specified,
1. Incoming parts and materials are operation, excessive over-stressing,
correct. noise, excessive effort, improper
2. Machinery will be built, installed, endangers operator, maintenance,
aadjusted, and maintained to increased cycle time, improper
specifications impared performance, specification,
3. All preceding steps in the loss of production, contamination,
sequence of operations have been partial or complete loss excessive heat,
executed to specifications. of function, excessive wear.
vibration, lack of
repeatability, excessive
backlash.

0
 Potential Page 71 of 76
Failure Mode and Effects Analysis
http://www.qimacros.com/free-lean-six-sigma-tips/fmea.html (Machine FMEA)
System: Name/number of system
Subsystem Name/number of subsystem Design
Component Name/number of component Responsibility: Name
Model: model years/programs Key Date: 7/15/2008
Core Team: Team members
Item/Function

Occurrence

Detection
Potential Current Machinery

Severity
Class
Potential Effect(s) of Cause(s) / Controls R. P.
Potential Failure Mode N.
Failure Mechanism(s) of -Prevention
Failure -Detection
Requirements
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Severity of Effect: Occurrence Failure/cycles Detection:
No Effect 1. None 1. Very low <1/900000 R(t)=98% MTBF=50x 1. Almost Cer
within spec limits 2. Very Minor 2. Low - 1/900000 R(t)=95% MTBF=20x 2. Very High
Downtime 0-10 min, no defects 3. Minor 3. Low - 1/540000 R(t)=90% MTBF=10x 3. High
Downtime 10-30 min, no defects 4. Very Low 4. Moderate - 1/360000 R(t)=85% MTBF=6x 4. Moderate High
 Page 72 of 76

Potential
Failure Mode and Effects Analysis
http://www.qimacros.com/free-lean-six-sigma-tips/fmea.html (Machine FMEA)
System: Name/number of system
Subsystem Name/number of subsystem Design
Component Name/number of component Responsibility: Name
Model: model years/programs Key Date: 7/15/2008
Core Team: Team members
Item/Function

Occurrence

Detection
Potential Current Machinery

Severity
Class
Potential Effect(s) of Cause(s) / Controls R. P.
Potential Failure Mode N.
Failure Mechanism(s) of -Prevention
Failure -Detection
Requirements
Downtime 30-60 min, 1hr of defects 5. Low 5. Moderate - 1/270000 R(t)=78% MTBF=4x 5. Moderate
Downtime and defects 1-2hrs. 6. Moderate 6. Moderate - 1/180000 R(t)=61% MTBF=2x 6. Low
Downtime > 4hrs, defects 2-4 hrs 7. High 7. High - 1/90000 R(t)=37% MTBF=Spec 7. Very Low
Downtime > 8 hrs, defects > 4 hrs 8. Very High 8. High - 1/36000 R(t)=19% MTBF=0.6x 8. Remote
Affects personnel 9. Hazardous with warning 9. Very High 1/900 R(t)=5% MTBF=0.3x 9. Very Remo
safety/regulations 10. Hazardous w/o warning 10. Very High >1/90 R(t)<1% MTBF=0.1x 10. Almost Imposs
 Page 73 of 76

AIAG Fourth Edition SAE J1739 Aug2002

FMEA Number Insert FMEA#
Page 1 of 1
Prepared by: who
FMEA Date: 7/15/2008
Re
co Action Results
m

Occurrence
Detection
me

Severity
Responsibility &
nd Actions Taken & R. P.
Target Completion N.
ed Completion Date
Date
Ac
tio
n(s
)
AIAG Fourth Edition SAE J1739 Aug2002 Page 74 of 76
FMEA Number Insert FMEA#
Page 1 of 1
Prepared by: who
FMEA Date: 7/15/2008
Re
co Action Results
m

Occurrence
Detection
me

Severity
Responsibility &
nd Actions Taken & R. P.
Target Completion N.
ed Completion Date
Date
Ac
tio
n(s Name of
De Actions and
) organization or
sig actual completion
n individual and date
act target completion
ion date
s
to
re
du
ce
se
ve
rit
y,
oc
cur
re
nc
e
an
d
de
tec
tio
n
rat
ing
s.
Se
ve
rit
y
of
9
or 0
 Page 75 of 76

AIAG Fourth Edition SAE J1739 Aug2002

FMEA Number Insert FMEA#
Page 1 of 1
Prepared by: who
FMEA Date: 7/15/2008
Re
co Action Results
m

Occurrence
Detection
me

Severity
Responsibility &
nd Actions Taken & R. P.
Target Completion N.
ed Completion Date
Date
Ac
tio
n(s 0
) 0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Detection: Stakeholder Effects of Failure Severity
1. Almost CerConsumer Owner Safety Problem 10
2. Very High (e.g., buyer) Major Owner Dissatisfaction 8
Moderate Owner Dissatisfaction 6
4. Moderate High Minor Owner Dissatisfaction 4
 Page 76 of 76

AIAG Fourth Edition SAE J1739 Aug2002

FMEA Number Insert FMEA#
Page 1 of 1
Prepared by: who
FMEA Date: 7/15/2008
Re
co Action Results
m

Occurrence
Detection
me

Severity
Responsibility &
nd Actions Taken & R. P.
Target Completion N.
ed Completion Date
Date
Ac
tio
n(s Customer
5. Moderate Plant Safety Problem 10
) (Manufacturer) Possible Recall 9
7. Very Low Line Stoppage 8
8. Remote Warranty Costs 7
9. Very RemoAIAG PPAP 4th Scrap 7
10. Almost Impossible Regulatory Penalty 7
Moderate Rework (<25%) 5
Plant Dissatisfaction 4
Minor Rework (<10%) 3