Introduction

Welcome to the FMEA Worksheet

This spreadsheet can be used to
1. Identify potential failure modes and their impact on product reliability.
2. Rank the potential defects to establish priority - The highest RPN value items deserve the most attention.
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. Released for review: 31-Jul-98
A. Dembski rev 1
 Introduction

t attention.
 Descriptions

Description of FMEA Worksheet

Protection:The spreadsheets are not protected or locked.

System Potential FMEA Number

Subsystem Failure Mode and Effects Analysis Prepared By
Component (Design FMEA) FMEA Date
Design Lead Key Date Revision Date
Core Team Page of

Action Results
Potential P

New RPN
New Occ
New Sev

New Det
S D R Responsibility &
Potential Failure Potential Effect(s) Cause(s)/ r Current Design Recommended
Item / Function e e P Target Completion Actions Taken
Mode(s) of Failure Mechanism(s) of o Controls Action(s)
v t N Date
Failure b
0 0
Coolant Crack/break. Leak 8 Over pressure 8 Burst, validation 1 64 Test included in J.P. Aguire 0
containment. Burst. Side wall pressure cycle. prototype and 11/1/95 E. Eglin
Hose connection. flex. Bad seal. production 8/1/96
Coolant fill. M Poor hose rete validation testing.
0 0
Write down each failure mode 0 Response Plans and Tracking 0
and potential consequence(s) 0 0
of that failure. 0 0
0 0
Risk Priority Number - The combined weighting
Severity - On a scale of 1- of Severity, Likelihood, and Detectability.
10, rate the Severity of each RPN
0 = Sev X Occ X Det 0
failure (10= most severe).
See Severity sheet.
0 0
0 0
Likelihood - Write down the Detectability 0- Examine the current 0
potential cause(s), and on a design, then, 0on a scale of 1-10, 0
scale of 1-10, rate the rate the Detectability of each failure
0 0
Likelihood of each failure (10 = least detectable). See
(10= most likely). See 0
Detectability sheet. 0
Likelihood sheet. 0 0
0 0

Page 3
 System Design Verification Process Potential FMEA Number Project III
Subsystem Failure Mode and Effects Analysis Prepared By Houston Mayer
Component (Design FMEA) FMEA Date 10/22/1999
Design Lead Houston Mayer Key Date Revision Date 8/21/2000
Core Team See Project III R1 Report Page 1 of 6

Action Results
P

New RPN
New Occ
New Sev

New Det
S Potential Cause(s)/ D R Responsibility &
Potential Failure Potential Effect(s) r Current Design Recommended
Item / Function e Mechanism(s) of e P Target Completion Actions Taken
Mode(s) of Failure o Controls Action(s)
v Failure t N Date
b
Customer sends System, Customer needs 7 Human error 1 Design 3 21 Use Closed 0
in a quote Software, not fully met by configuration configuration 10/21/99
request for Integration and delivered system. tool. tool when
product. Shipping available.
requirements
overlooked by
customer.

Requirement Data entry error System 3 Human error 1 Order verified by 3 9 Continue order Closed 0
entered and compatability a configuration verification by 10/21/99
verified by Inside requirements not tool. configuration
Sales in config. evaluated by tool.
tool. config. tool.

Sales identifies Specific packing, On time delivery 7 Requirements 3 Customer 3 63 Publish Jun-00 Customer 0
need for CII or labeling and and integraty of Overlooked. Inspection comprehensive shipping
SHC shipping the product may Instruction/ procedure for requirements
requirements be compramised Special Handling the 1st Article reviewed by
may not be fully if this issue is Codes Process Process. quality
addressed. not addressed. 033-001-02 assurance in 1st
Article process.

Position of the Loss of business 1 Requirements 5 CII 033-001-006 1 5 Revisit contents Sep-00 OPEN 8/21/00
DHR in ICD label with the Overlooked. of GE CII 033-
packet not customer. 001-006 to
identified by GE. assure all
Requirment in requirements are
Purchase clearly
Specification for commumicated
mousepad, but to the warehouse
not identified on operators and
Bill of Material. quality
ICD Card technicians
content using these
requirements not documents.
identified in
Build Procedure.

Houston Mayer 4
Six Sigma Blackbelt
August 21, 2000
 QA and Pack Specific packing, Customer's full 7 Requirements 3 Customer 3 63 Continue current Closed 0
and Ship Team labeling and expectations overlooked. requirements pracices. 10/25/99
reviews shipping may not be physically
customer requirements realized. verified by
requirements may not be fully quality
during a 1st addressed. assurance
Article. during the 1st
Article process.

Inside sales Data entry error Order Processing 1 Human Error 1 Customer 3 3 Continue current Closed 1/25/00 0
submits Sales Delay requirements practices.
Order verified by a
Authorization TECenter
request to engineer.
TECenter.

TECenter Requirements Customer's full 3 Requirements 6 Customer 3 54 Continue current Closed 0

Engineer reviews overlooked by expectations Overlooked. requirements practices. 10/25/99
the design to Engineer may not be verified by a
determain if realized. TECenter
additional data engineer.
is required.

Appropriate Appropriate Order Processing 1 Process Failure 1 Individuals are 1 1 Continue current Closed 1/25/00 0
individuals are individuals not Delay contacted to practices.
contacted to available. resolve issues.
resolve issues.

Design Review is Requirements Customer's full 1 Process Failure 1 Customer 1 1 Continue current Closed 1/25/00 0
completed. may not be expectations requirements pracices.
complete may not be verified by a
realized. TECenter
engineer.

Another engineer Requirements Customer's full 7 Process Failure 3 Customer 3 63 Continue current Closed 0
performs quality overlooked by expectations requirements pracices. 10/25/99
check of the two Engineer may not be verified by a
design. realized. TECenter
engineer.

Completed Design Order Processing 1 Process Failure 1 Verification is 1 1 Continue current Closed 1/25/00 0
design verification Delay sent to pracices.
verification is misrouted appropriate
sent to organization.
appropriate
organization.

Houston Mayer 5
Six Sigma Blackbelt
August 21, 2000
 Requirements Requirements Customer's full 1 Process Failure 1 Requirements 1 1 Continue current Closed 1/25/00 0
are defined and may be missed expectations are defined and pracices.
capability to or capibilty to may not be to meet
meet/ accept meet realized. requirements.
requirements. overestamated

Inside Sales Wrong price and Customer's full 3 Process Failure 1 Price provided to 1 3 Continue current Closed 1/25/00 0
quotes price and availability expectations customer pracices.
availability provided to may not be
customer realized.

Customer sends Order misrouted Order Processing 1 Process Failure 1 Reprocess Order 1 1 Continue current Closed 1/27/00 0
in purchase Delay pracices.
order.
Inside sales Data Entry Error Order Processing 3 Human Error 1 Reprocess Order 1 3 Continue current Closed 1/27/00 0
places order on Delay pracices.
system.

Order approved Approval not Order Processing 1 Process Failure 1 Expidite Process 1 1 Continue current Closed 1/27/00 0
by Asset timely Delay pracices.
Management.

Order approved Approval not Order Processing 1 Process Failure 1 Expidite Process 1 1 Continue current Closed 1/27/00 0
by credit. timely Delay pracices.

Determaination All product (1) Product 5 Needed 3 Assure product 1 15 Continue current Closed 0
made that required for the delivery date components are availability practices. 10/25/99
product is order may not be requirements not available at before the order
available for available at the may not be met. the time of need. commitment is
build. start of the (2) Workspace given to
build. occupied for an customer.
order awaiting
Product is not
available for
integration of
other orders.

Inside sales Shipdates may Customer's full 1 Needed 1 Expidite Process 1 1 Continue current Closed 1/27/00 0
expedites with not be accurate expectations components are practices.
Asset to provide may not be not available at
ship date. realized. the time of need.

Order approved e-mail may be Order Processing 1 Process Failure 1 Expidite Process 1 1 Continue current Closed 1/27/00 0
by Asset Mgmt. misrouted Delay practices.
and e-mail sent
to Integration.

Houston Mayer 6
Six Sigma Blackbelt
August 21, 2000
 Project Manager Order processing Customer and 3 Processing 1 Project Manager 1 3 Continue current Closed 0
reviews order for requirements processing needs requirements order review. practices. 10/25/99
special or may be not identified overlooked.
internal overlooked could prevent
instructions. timely
processing of the
order.

Build document Documents do Order Processing 5 Needed 3 Expidite Process 3 45 Continue current Closed 1/27/00 0
bill of material not match Delay components are Integration practices.
matched with not available at Center
SCN. the time of need. Operations
Manual 093-
009-OPSMNL

Stock availability stock availability Customer's full 3 Needed 1 Expidite Process 1 3 Continue current Closed 1/27/00 0
is checked and and dates may expectations components are practices.
delivery dates be inaccurate may not be not available at
are aquired for realized. the time of need.
non stock items.

Order is Order may be Order Processing 1 Process Failure 1 Expidite Process 1 1 Continue current Continue current
forwarded to misrouted Delay practices. practices.
Production
Engineer for
review.
Determanation Need for 1st Customer's full 7 Requirements 3 Individuals are 5 105 Continue current Continue current
made for a 1st build may be expectations Overlooked. contacted to practices. practices.
Article build. overlooked may not be resolve issues.
realized.
Build document Requirements Customer's full 3 Requirements 3 Individuals are 3 27 Continue current Continue current
is reviewed and may be expectations Overlooked. contacted to practices. practices.
verified. overlooked may not be resolve issues.
realized.
Project Sales may not Order Processing 3 Requirements 1 Individuals are 1 3 Continue current Continue current
management receive order Delay Overlooked. contacted to practices. practices.
notifies sales status resolve issues.
with status of
order.
Asset Items may not Order Processing 3 Needed 1 Expidite Process 1 3 Continue current Closed 1/27/00
management be ordered Delay components are practices.
places order for not available at
non stock items. the time of need.

Order is Order may not Order Processing 3 Requirements 1 Individuals are 1 3 Continue current Closed 1/27/00
scheduled for be entered in Delay Overlooked. contacted to practices.
production. schedule resolve issues.

Whse Operator Parts may not Order Processing 3 Requirements 3 Individuals are 1 9 Continue current Closed 1/27/00
reviews parts to match Delay Overlooked. contacted to practices.
SOA & SCN. requirement resolve issues.

Houston Mayer 7
Six Sigma Blackbelt
August 21, 2000
 Whse. Operator All parts may not Order Processing 3 All components 3 Individuals are 3 27 Continue current Closed 1/27/00
Unpack,Iinspect reach integration Delay are not available contacted to practices.
& Kit order. at the time of resolve issues.
need. Integration
Kitting and
Packing 153-
001-01

Techs. Check Parts may not Order Processing 5 All components 3 Individuals are 1 15 Continue current Closed 1/27/00
product against match Delay are not available contacted to practices.
SOW and build requirement at the time of resolve issues.
instructions. need.

Integration Materials may Order Processing 7 All components 3 QA Inspection 3 63 Continue current Closed 1/27/00
Techs. inspect not be compliant Delay are not available and Test practices.
parts and at the time of Procedure 103-
chassis. need. 001-03

No NT Resource Loss of business 1 Requirements 1 QA Inspection 5 5 Update Build Closed 8/21/00

Kit with the Overlooked. and Test Procedures to
Missing Video customer. Procedure 103- clearly define
Board 001-03 product
requirements
specific to the
model being
integrated.

Techs. Integrate System may be Order Processing 7 Individuals are 7 QA Inspection 3 147 Continue current Closed 1/27/00
& Power-Up integrated Delay contacted to and Test practices.
System incorrectly resolve issues. Procedure 103-
001-03

Integration System and Order Processing 10 Needed 10 QA Inspection 1 100 Continue current Closed 1/27/00
Techs. Test parts may not be Delay components are and Test practices.
system. compliant not available at Procedure 103-
the time of need. 001-03

Quality techs. Specific build On time delivery 5 Requirements 1 Individuals are 5 25 Continue current
inspect product requirements and integraty of Overlooked. contacted to practices.
for build may not be fully the product may resolve issues.
requirements. addressed. be compramised
if this issue is
not addressed.

Houston Mayer 8
Six Sigma Blackbelt
August 21, 2000
 IO panel not Loss of business 1 Human Error 5 Build Procedure 5 25 Update Build Closed 8/21/00
installed with the for individual Procedures to
Label on CPU customer. PathSpeed Model clearly define
Incorrect product
No feet or other requirements
components specific to the
installed model being
No extension integrated.
cables
Missing cables
IO panel gasket
not installed
Wrong ICD cards
provided
Dome calibrater
included

Product serial Numbers may be Order Processing 3 Requirements 3 Individuals are 1 9 Continue current Closed 1/27/00
numbers incorrect Delay Overlooked. contacted to practices.
scanned into resolve issues.
Genesis.
Change made Control of Order Processing 1 Requirements 1 Individuals are 1 1 Continue current Closed 1/27/00
after batch requirements Delay Overlooked. contacted to practices.
release may be lost resolve issues.

Order placed on Shiping Order Processing 3 Requirements 3 Individuals are 1 9 Continue current Closed 1/27/00
hold when deadlines may Delay Overlooked. contacted to practices.
change is made. not be met resolve issues.

Design Process Control of Order Processing 3 Process Failure 1 Individuals are 1 3 Continue current Closed 1/27/00
reinitiates requirements Delay contacted to practices.
may not be resolve issues.
complete
Whse. invoices Wrong Shipping On time delivery 7 Process Failure 1 Individuals are 1 7 Continue current Closed 1/27/00
and ships order method may be and integraty of contacted to practices.
per customer's used the product may resolve issues.
shipping be compramised
method. if this issue is
not addressed.

Quality techs. Specific packing, On time delivery 10 Requirements 3 Customer 3 90 Continue current Closed 1/25/00
inspect labeling and and integraty of Overlooked. Inspection pracices.
shipment for shipping the product may Instruction/
CII/SHC requirements be compramised Special Handling
requirements. may not be fully if this issue is Codes Process
addressed. not addressed. 033-001-02

Houston Mayer 9
Six Sigma Blackbelt
August 21, 2000
 Label on outside Loss of business 1 Human Error 3 CII 033-001-006 3 9 Revisit contents 9/11/2000
of box did not with the of GE CII 033-
match S/N on customer. 001-006 to
CPU. assure all
requirements are
clearly
commumicated
to the warehouse
operators and
quality
technicians
using these
documents.

Product ships to Products On time delivery 7 Needed 3 Individuals are 7 147 Continue current Closed 1/27/00
customer. misshipped and integraty of components are contacted to practices.
the product may not available at resolve issues.
be compramised the time of need.
if this issue is
not addressed.

Coordinator Documents not Documents may 3 Documents may 1 Individuals are 1 3 Continue current Closed 1/25/00
closes project & filed correctly not be not be contacted to pracices.
files quality retrievable retrievable resolve issues.
records.

Houston Mayer 10
Six Sigma Blackbelt
August 21, 2000
 Severity

Effect SEVERITY of Effect Ranking

Hazardous without Very high severity ranking when a potential failure mode 10
warning affects safe system operation without warning
Hazardous with Very high severity ranking when a potential failure mode 9
warning affects safe system operation with warning
Very High System inoperable with destructive failure without 8
compromising safety
High System inoperable with equipment damage 7

Moderate System inoperable with minor damage 6

Low System inoperable without damage 5

Very Low System operable with significant degradation of performance 4

Minor System operable with some degradation of performance 3

Very Minor System operable with minimal interference 2

None No effect 1

Page 11
 Probability

PROBABILITY of Failure Failure Prob Ranking

Very High: Failure is almost inevitable >1 in 2 10
1 in 3 9
High: Repeated failures 1 in 8 8
1 in 20 7
Moderate: Occasional failures 1 in 80 6
1 in 400 5
1 in 2,000 4
Low: Relatively few failures 1 in 15,000 3
1 in 150,000 2
Remote: Failure is unlikely <1 in 1,500,000 1

Page 12
 Detectability

Detection Likelihood of DETECTION by Design Control Ranking

Absolute Design control cannot detect potential cause/mechanism and 10
Uncertainty subsequent failure mode
Very Remote Very remote chance the design control will detect potential 9
cause/mechanism and subsequent failure mode
Remote Remote chance the design control will detect potential 8
cause/mechanism and subsequent failure mode
Very Low Very low chance the design control will detect potential 7
cause/mechanism and subsequent failure mode
Low Low chance the design control will detect potential 6
cause/mechanism and subsequent failure mode
Moderate Moderate chance the design control will detect potential 5
cause/mechanism and subsequent failure mode
Moderately High Moderately High chance the design control will detect 4
potential cause/mechanism and subsequent failure mode
High High chance the design control will detect potential 3
cause/mechanism and subsequent failure mode
Very High Very high chance the design control will detect potential 2
cause/mechanism and subsequent failure mode
Almost Certain Design control will detect potential cause/mechanism and 1
subsequent failure mode

Page 13
 EXAMPLE

System
Subsystem
Component
Design Lead
Core Team

Potential Failure
Item / Function
Mode(s)

Seals
Coolant
containment.
Hose connection.
Coolant fill. M

Sensor mount. Compression set

Seal
Sensor mount. Loosen during
Seal sensor
assembly/servic
e

Sensor mount. Damaged

Seal internal thread

Sensor mount. Damaged

Seal external thread

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

Page 14
 EXAMPLE

System
Subsystem
Component
Design Lead
Core Team

Potential Failure
Item / Function
Mode(s)

Coolant containment. Crack/break. Burst.

Hose connection. Side wall flex. Bad
Coolant fill. M seal. Poor hose rete

Hold fluid, flow path, Stress crack

Heat transfer
structure

Hold fluid, flow path, Stress crack

Heat transfer
structure

Hold fluid, flow path, Stress crack

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

Hold fluid, flow path, Corrosion

Heat transfer
structure

Hold fluid, flow path, Puncture

Heat transfer
structure

Hold fluid, flow path, Seam fail

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

Page 15
 EXAMPLE

System
Subsystem
Component
Design Lead
Core Team

Potential Failure
Item / Function
Mode(s)

Hold fluid, flow path, Plugged

Heat transfer
structure

Hold fluid, flow path, Ballooning

Heat transfer
structure

Page 16
 EXAMPLE

Potential FMEA Number

Failure Mode and Effects Analysis Prepared By
(Design FMEA) FMEA Date
Key Date Revision Date
Page of

Action Results
P

New Occ
New Sev

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

0
0

Leak 8 Gasket material 7 Pressure cycle 1 56 Use imported

w/cold shock. material
Leak. Fall inside 8 Fitting not held 2 Added rib. 1 16 Implement J.P. Aguire
tank in place holding rib in 11/1/95
design. New
fitting design.
Prototype
validation.

Cannot install 5 Damaged during 2 1 10

sensor installation or
transportation

Cannot install 4 Damaged during 3 1 12 Damaged fitting

wire nut shipment to not used by
piracicaba Piracicaba

Leak 8 Over pressure 8 Burst, validation 1 64 Test included in J.P. Aguire 11/1/95
pressure cycle. prototype and E. Eglin 8/1/96
production validation
testing.
Failed mount 5 Vibration 9 Vibration w/road 3 135 Obtain GMB vibration J.P. Aguire
tapes road tape.

Page 17
 EXAMPLE

Potential FMEA Number

Failure Mode and Effects Analysis Prepared By
(Design FMEA) FMEA Date
Key Date Revision Date
Page of

Action Results
P

New Occ
New Sev

New Det
S Potential Cause(s)/ D R Responsibility &
Potential Effect(s) r Current Design Recommended
e Mechanism(s) of e P Target Completion Actions Taken
of Failure o Controls Action(s)
v Failure t N Date
b
Hose leak 6 Overpressure. Poor 5 Burst, validation 2 60 Obtain GMB clamps J.P. Aguire 12/1/95
clamp pressure cycle and clamping
w/GMB clamps. specification.

Air conditioning does This is a test of the 0 Operator instruction

not work. Sudden ADD POTENTIAL
refrigerant loss. CAUSE/MECHANIS
M OF FAILURE
system functionality
Air conditioning does This is a test of the 0 This is a test of the
not work. Sudden ADD POTENTIAL ADD
refrigerant loss. CAUSE/MECHANIS RECOMMENDED
M OF FAILURE ACTION system
system functionality functionality
Leak. Loss of heat 8 Wicking. Material 7 Thermal cycle 1 56 Included in Product E. Eglin 8/1/96
transfer. strength Specification

Air conditioning does this is a test while 0

not work. Sudden dan is here
refrigerant loss.

Leak. Loss of heat 8 Coolant quality. 7 SWAT, service 5 280 Brazilian coolant to J.P. Aguirre 11/1/95 Coolant ordered
transfer. Contamination. simulation. Coolant be evaluated. Zince
Environment - int/ext. evaluation. lined tubes may need
to be released.
Simulated service
test w/GMB coolant
to be performed.
Leak. Loss of heat 8 External damage. 10 Leak test. Simulated 1 80 100% cores tested in E. Eglin 8/1/96
transfer. Coolant velocity. No service. production. Simulated
reinf sawcut. service included in
Product Specificatin.

Leak. Loss of heat 5 Environment - int/ext. 1 SWAT, service 1 5 Included in Product E. Eglin 8/1/96
transfer. simulation. Specification.

Leak. Loss of heat 8 Over pressure 2 Burst/leak pressure 5 80 GMB to study engine GMB 12/1/95 Study originated
transfer. contamination. cleanliness.

Page 18
 EXAMPLE

Potential FMEA Number

Failure Mode and Effects Analysis Prepared By
(Design FMEA) FMEA Date
Key Date Revision Date
Page of

Action Results
P

New Occ
New Sev

New Det
S Potential Cause(s)/ D R Responsibility &
Potential Effect(s) r Current Design Recommended
e Mechanism(s) of e P Target Completion Actions Taken
of Failure o Controls Action(s)
v Failure t N Date
b
Loss of heat transfer. 8 Contamination. 7 1 56 GMB coolant to be J.P. Aguirre 11/1/95 Coolant ordered
Leakage due to Coolant quality. evaluated. GMB to
increase flow velocity study engine
cleanliness.
Leak. Loss of heat 5 Over pressure 9 8 360 GMB to study engine GMB 12/1/95
transfer. contamination. cleanliness.
Clustomer profile to
be determined.
0
0
0

Page 19
 EXAMPLE

on Results
New RPN

0
0

Page 20
 EXAMPLE

on Results
New RPN

Page 21
 EXAMPLE

on Results
New RPN

0
0
0

Page 22