Severity, Occurrence, and Detection Criteria for Process FMEA

SUGGESTED DETECTION EVALUATION CRITERIA

SEVERITY EVALUATION CRITERIA
DETECTION CRITERIA SUGGESTED RANGE OF RNK.
EFFECT CRITERIA: Severity of Effect R NK A B C DETECTION METHODS
This ranking results when a potential failure mode results in a final Almost Absolute certainty of Non -
Detection
Cannot detect or is not checked. 10
customer and/or a manufacturing/assembly plant defect. The final Impossible
customer should always be considered first. If both occur, use the Controls will probably not Control is achieved with indirect or random
higher of the two severities. Very Remote detect. checks only. 9
Customer Effect Manufacturing/Assembly Effect Controls have poor chance
Remote of detection.
Control is achieved with visual inspection only. 8
Hazardous- Very high severity ranking when a potential failure Or may endanger operator (machine or assembly)
mode effects safe vehicle operation and/or involves without warning. 10 Very Low Controls have poor chance Control is achieved with double visual
7
without noncompliance with government regulation of detection. inspection only.
warning without warning. Control is achieved with charting methods, such
Low Controls may detect.
as SPC (Statistical Process Control). 6
Hazardous- Very high severity ranking when a potential failure Or may endanger operator (machine or assembly)
mode effects safe vehicle operation and/or involves with warning. 9 Control is based on variable gauging after parts
with noncompliance with government regulation with have left the station, OR Go/No Go gauging
warning warning.
Moderate Controls may detect.
performed on 100% of the parts after parts have 5
left the station.
Vehicle/item inoperable (loss of primary function) Or 100% of product may have to be scrapped, or
vehicle/item repaired in repair department with a
8 Moderately Error Detection in subsequent operations, OR
Very High Controls have a good chance
repair time greater than one hour. to detect.
gauging performed on set-up and first-place 4
High check (for set-up Causes only).
Vehicle/item operable but at a reduced level of Or product may have to be sorted and a portion
performance. Customer very dissatisfied. (less than 100%) scrapped or vehicle/item repaired 7 Error Detection in -station, OR error Detection in
High Controls have a good chance subsequent operations by multiple layers of
in repair department with a repair time between High to detect. acceptance; supply, select, install, verify.Cannot 3
half an hour and an hour.
accept discrepant part.
Vehicle/item operable but Comfort/Convenience Or a portion (less than 100%) of the product may
item(s) inoperable. Customer dissatisfied. have to be scrapped with no sorting, or vehicle 6 Controls almost certain to
Error Detection in -station (automatic gauging
Moderate /item repaired in repair department with a repair Very High with automatic stop feature). Cannot pass 2
detect.
time less than half an hour. discrepant part.
Discrepant parts cannot be made because item
Vehicle/Item operable but Comfort/Convenience Or 100% of product may have to be reworked, or
items operable at a reduced level of performance. vehicle/item repaired off-line but does not go to
5 Very High Controls certain to detect. has been error proofed by progress/product 1
Low design.
Customer somewhat dissatisfied. repair department.

Fit & Finish/Squeak & Rattle item does not Or the product may have to be sorted with no
Very Low conform. Defect noticed by most customers scrap, and a portion (less than 100%) reworked.
4 Inspection Types: A = Error Proofed NOTE: The ranking value of 1 is reserved for
B = Gauging “Almost Certain.”
(greater than 75%).
C = Manual Inspection
Fit & Finish/Squeak & Rattle item does not Or a portion (less than 100%) of the product may
Minor conform. Defect noticed by 50% of customers. have to be reworked with no scrap, on-line but out- 3
of-station. SUGGESTED OCCURRENCE EVALUATION CRITERIA
Fit & Finish/Squeak & Rattle item does not Or a portion (less than 100%) of the product may
Very conform. Defect noticed by discriminating have to be reworked with no scrap, on-line but in-
2 Probability of Likely Failure Rates Ranking
Minor customers (less than 25%). station. Failure
No discernible effect. Or slight inconvenience to operation or operator, or
None no effect. 1 ≥ 100 per thousand pieces 10
Very High: Persistent failures
50 per thousand pieces 9
RPN THRESHOLD 20 per thousand pieces 8
There is no threshold value for RPNs. In other words, there is no High: Frequent failures
10 per thousand pieces 7
value above which it is mandatory to take a Recommended Action
or below which the team is automatically excused from an action. 5 per thousand pieces 6
Moderate: Occasional failures 2 per thousand pieces 5
1 per thousand pieces 4
0.5 per thousand pieces 3
(313) 565 - 6266 Low: Relatively few failures
US (888) FOR - FMEA
*Note: Zero (0) rankings 0.1 per thousand pieces 2
CDN (877) 609-0999 for Severity, Occurrence
AUS (03) 9585 - 6423 or Detection are not allowed Remote: Failure is unlikely ≤ 0.01 per thousand pieces 1
www.quality-one.com
 FMEA - Quick Reference Guide
Potential
ITEM: FMEA Number:
Failure Mode and Effects Analysis Page 1 of 1
Model Year/Vehicle (s): Process Responsibility: (Process FMEA) Prepared by: Lee Dawson
Core Team: M. Moore, M. Weber, D. Wojcik, L. Dawson Key Date: FMEA Date (orig.):
Process Potential Current Action Results
S Cl
Potential Potential O D Responsibility
c e R.
Cause(s)/ Process Recommended Actions S O D R.
Failure Effect(s) of e a c t P. & Target
Controls Action(s) Taken e c e P.
Mode Failure v ss Mechanism(s) u e N. Completion Date
Function Failure r Prevent c v c t N.
Detect
OP#10 must assemble cross FMEA not • Product liability Inadequate FMEA • Mistake • APQP Call an FMEA Process engineer team FMEA performed
10 CC Proofing Checklist 5 250
functional Team and Develop adequately • Customer development 5 facilitator to leader or project under the supervision 10 1 2 20
• Automatic • FMEA Review
FMEA. performed; dissatisfaction • Cross functional reduce time required manager; and leadership of
Visual Process
•SAEJ 1739 Guidelines • Reduced performance team not assembled Systems • Management and improve quality ASAP an expert/certified
•APQP Specific Team of system or • Facilitation not • Proximity Review Process of the FMEA process FMEA facilitator
Members component used Switch • Control Plan
Must provide an FMEA • Potential risk of • FMEA expertise is entries
which determines process injury limited
risk and addresses • Reduce level of • Lack of adequate Actions should: Brief action
• eliminate failure • Name of team
confirmed significant analysis of process FMEA Training result Recalculate RPN, after
characteristic selection: • Inconsistent product/ mode SEV=9/10 member to
• eliminate causes description action has been
Measurable: high return rate carry issue.
Detect on CC Date action taken
• Torque • Name of
Planned Evaluation • reduce occurrence taken • occurrence
Customer Method to/from • improve evaluation champion
Brainstorm causes • detection
focus/experience • Control Plan “detection • Date action
• man Note: severity will
• Verb-noun • end user • Tools reduction last desired
• material • Mistake Proofing likely stay the same
• measurable • assembler • method option” completion
Note: must have written
Anti function Instruction unless failure mode is
is desirable • maker • machine
for functional Prevent eliminated
• objective • environment • Reduce Occurrence
• regulatory
approach Determine Root
• subjective body
• full cause if CC
• partial
See Occurrence See Detection
• intermittent See Severity Chart on Chart on
• excess function
Chart on opposite side opposite side
opposite side
Actions are Required: Critical & Significant TM

(by Priority) Characteristics Action Guidelines

FMEA EXPRESS
• Complete FMEAs more quickly
1.) Confirmed CC is a 10 • Address high-risk potential
Top 20% of Failure failure modes first
Critical Characteristic to be 1.) Confirmed Critical Characteristic
9 Modes by RPN • Use a cross-functional FMEA
addressed on Control
8
team approach
Plan)
S 2.) Confirmed Significant
7
e Characteristic; Action
R
v 6 Required
2.) An SC is a confirmed P
Significant Characteristic to e 5 N
be addressed on Control r
4
i ANNOYANCE
Plan) US (888) FOR-FMEA
t 3 ZONE
y 3.) RPN-Top US (313) 565 - 6266
2 CDN (877) 609 – 0999
20% by pareto Failure Modes
3.) For the top 20% Failure 1 AUS (03) 9585 - 6423
Modes / Causes (Pareto by 1 2 3 4 5 6 7 8 9 10 www.quality-one.com
RPN) Occurrence
© 1998 (REV: 11/2000)