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
 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

Coolant Crack/break. Leak 8 Over pressure 8 Burst, validation 1 64 Test included in J.P. Aguire
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.

Write down each failure mode Response Plans and Tracking

and potential consequence(s)
of that failure.
Risk Priority Number - The combined weighting of
Severity - On a scale of 1- Severity, Likelihood, and Detectability.
10, rate the Severity of each RPN = Sev X Occ X Det
failure (10= most severe).
See Severity sheet.

Likelihood - Write down the Detectability - Examine the current

potential cause(s), and on a design, then, on a scale of 1-10, rate
scale of 1-10, rate the the Detectability of each failure
Likelihood of each failure (10 = least detectable). See
(10= most likely). See Detectability sheet.

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
in a quote Software, not fully met by configuration configuration 10/21/99
request for Integration and delivered tool. tool when
product. Shipping system. available.
requirements
overlooked by
customer.
Requirement Data entry error System 3 Human error 1 Order verified by 3 9 Continue order Closed
entered and compatability a configuration verification by 10/21/99
verified by requirements tool. configuration
Inside Sales in not evaluated by tool.
config. tool. config. tool.

Sales identifies Specific packing, On time delivery 7 Requirements 3 Customer 3 63 Publish Jun-00 Customer
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 with the Overlooked. of GE CII 033-
label packet not customer. 001-006 to
identified by GE. assure all
Requirment in requirements
Purchase are clearly
Specification for commumicated
mousepad, but to the
not identified on warehouse
Bill of Material. operators and
ICD Card quality
content technicians
requirements using these
not identified in documents.
Build Procedure.

Houston Mayer
Six Sigma Blackbelt
August 21, 2000 4
QA and Pack Specific packing, Customer's full 7 Requirements 3 Customer 3 63 Continue Closed
and Ship Team labeling and expectations overlooked. requirements current 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 1 Human Error 1 Customer 3 3 Continue Closed 1/25/00
submits Sales Processing Delay requirements current
Order verified by a practices.
Authorization TECenter
request to engineer.
TECenter.

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

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

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

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

Another Requirements Customer's full 7 Process Failure 3 Customer 3 63 Continue Closed

engineer overlooked by expectations requirements current pracices. 10/25/99
performs quality two Engineer may not be verified by a
check of the realized. TECenter
design. engineer.

Completed Design Order 1 Process Failure 1 Verification is 1 1 Continue Closed 1/25/00

design verification Processing Delay sent to current pracices.
verification is misrouted appropriate
sent to organization.
appropriate

Houston Mayer
Six Sigma Blackbelt
August 21, 2000 5
Requirements Requirements Customer's full 1 Process Failure 1 Requirements 1 1 Continue Closed 1/25/00
are defined and may be missed expectations are defined and current 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 Closed 1/25/00
quotes price and availability expectations customer current pracices.
availability provided to may not be
customer realized.

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

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

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

Determaination All product (1) Product 5 Needed 3 Assure product 1 15 Continue Closed
made that required for the delivery date components are availability current 10/25/99
product is order may not requirements not available at before the order practices.
available for be available at may not be met. the time of need. commitment is
build. the 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 Closed 1/27/00
expedites with not be accurate expectations components are current
Asset to provide may not be not available at practices.
ship date. realized. the time of need.

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

Houston Mayer
Six Sigma Blackbelt
August 21, 2000 6
Project Manager Order Customer and 3 Processing 1 Project Manager 1 3 Continue Closed
reviews order for processing processing requirements order review. current 10/25/99
special or requirements needs not overlooked. practices.
internal may be identified could
instructions. overlooked prevent timely
processing of the
order.
Build document Documents do Order 5 Needed 3 Expidite Process 3 45 Continue Closed 1/27/00
bill of material not match Processing Delay components are Integration current
matched with not available at Center practices.
SCN. the time of need. Operations
Manual 093-009-
OPSMNL
Stock stock availability Customer's full 3 Needed 1 Expidite Process 1 3 Continue Closed 1/27/00
availability is and dates may expectations components are current
checked and be inaccurate may not be not available at practices.
delivery dates realized. the time of need.
are aquired for
non stock items.
Order is Order may be Order 1 Process Failure 1 Expidite Process 1 1 Continue Continue
forwarded to misrouted Processing Delay current current
Production practices. practices.
Engineer for
review.
Determanation Need for 1st Customer's full 7 Requirements 3 Individuals are 5 105 Continue Continue
made for a 1st build may be expectations Overlooked. contacted to current current
Article build. overlooked may not be resolve issues. practices. practices.
realized.
Build document Requirements Customer's full 3 Requirements 3 Individuals are 3 27 Continue Continue
is reviewed and may be expectations Overlooked. contacted to current current
verified. overlooked may not be resolve issues. practices. practices.
realized. 3 Continue
Project Sales may not Order 3 Requirements 1 Individuals are 1 Continue
management receive order Processing Delay Overlooked. contacted to current current
notifies sales status resolve issues. practices. practices.
with status of
order.
Asset Items may not Order 3 Needed 1 Expidite Process 1 3 Continue Closed 1/27/00
management be ordered Processing Delay components are current
places order for not available at practices.
non stock items. the time of need.
Order is Order may not Order 3 Requirements 1 Individuals are 1 3 Continue Closed 1/27/00
scheduled for be entered in Processing Delay Overlooked. contacted to current
production. schedule resolve issues. practices.
Whse Operator Parts may not Order 3 Requirements 3 Individuals are 1 9 Continue Closed 1/27/00
reviews parts to match Processing Delay Overlooked. contacted to current
SOA & SCN. requirement resolve issues. practices.

Houston Mayer
Six Sigma Blackbelt
August 21, 2000 7
Whse. Operator All parts may Order 3 All components 3 Individuals are 3 27 Continue Closed 1/27/00
Unpack,Iinspect not reach Processing Delay are not available contacted to current
& Kit order. integration at the time of resolve issues. practices.
need. Integration
Kitting and
Packing 153-
001-01
Techs. Check Parts may not Order 5 All components 3 Individuals are 1 15 Continue Closed 1/27/00
product against match Processing Delay are not available contacted to current
SOW and build requirement at the time of resolve issues. practices.
instructions. need.

Integration Materials may Order 7 All components 3 QA Inspection 3 63 Continue Closed 1/27/00
Techs. inspect not be compliant Processing Delay are not available and Test current
parts and at the time of Procedure 103- practices.
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 7 Individuals are 7 QA Inspection 3 147 Continue Closed 1/27/00
& Power-Up integrated Processing Delay contacted to and Test current
System incorrectly resolve issues. Procedure 103- practices.
001-03
Integration System and Order 10 Needed 10 QA Inspection 1 100 Continue Closed 1/27/00
Techs. Test parts may not be Processing Delay components are and Test current
system. compliant not available at Procedure 103- practices.
the time of need. 001-03
Quality techs. Specific build On time delivery 5 Requirements 1 Individuals are 5 25 Continue
inspect product requirements and integraty of Overlooked. contacted to current
for build may not be fully the product may resolve issues. practices.
requirements. addressed. be compramised
if this issue is
not addressed.

Houston Mayer
Six Sigma Blackbelt
August 21, 2000 8
 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 clearly define
Incorrect Model 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 Order 3 Requirements 3 Individuals are 1 9 Continue Closed 1/27/00
numbers be incorrect Processing Delay Overlooked. contacted to current
scanned into resolve issues. practices.
Genesis.
Change made Control of Order 1 Requirements 1 Individuals are 1 1 Continue Closed 1/27/00
after batch requirements Processing Delay Overlooked. contacted to current
release may be lost resolve issues. practices.
Order placed on Shiping Order 3 Requirements 3 Individuals are 1 9 Continue Closed 1/27/00
hold when deadlines may Processing Delay Overlooked. contacted to current
change is made. not be met resolve issues. practices.
Design Process Control of Order 3 Process Failure 1 Individuals are 1 3 Continue Closed 1/27/00
reinitiates requirements Processing Delay contacted to current
may not be resolve issues. practices.
Whse. invoices complete
Wrong Shipping On time delivery 7 Process Failure 1 Individuals are 1 7 Continue Closed 1/27/00
and ships order method may be and integraty of contacted to current
per customer's used the product may resolve issues. practices.
shipping be compramised
method. if this issue is
not addressed.

Quality techs. Specific packing, On time delivery 10 Requirements 3 Customer 3 90 Continue Closed 1/25/00
inspect labeling and and integraty of Overlooked. Inspection current 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
Six Sigma Blackbelt
August 21, 2000 9
 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
Product ships to Products On time delivery 7 Needed 3 Individuals are 7 147 Continue Closed 1/27/00
customer. misshipped and integraty of components are contacted to current
the product may not available at resolve issues. practices.
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 Closed 1/25/00
closes project & filed correctly not be not be contacted to current pracices.
files quality retrievable retrievable resolve issues.
records.

Houston Mayer
Six Sigma Blackbelt
August 21, 2000 10
 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
Severity

Page 12
Severity

Page 13
Severity

Page 14
Severity

Page 15
Severity

Page 16
 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 17
 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 18
 EXAMPLE

System Potential
Subsystem Failure Mode and Effects Analysis
Component (Design FMEA)
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

Page 19
 EXAMPLE

System Potential
Subsystem Failure Mode and Effects Analysis
Component (Design FMEA)
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

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

Page 20
 EXAMPLE

System Potential
Subsystem Failure Mode and Effects Analysis
Component (Design FMEA)
Design Lead
Core Team

Potential Failure
Item / Function
Mode(s)

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
Hold fluid, flow path, Plugged
Heat transfer
structure

Hold fluid, flow path, Ballooning

Heat transfer
structure

Page 21
 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 RPN
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

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.

Page 22
 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 RPN
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
Failed mount 5 Vibration 9 Vibration w/road 3 135 Obtain GMB vibration J.P. Aguire
tapes road tape.

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 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 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

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.

Page 23
 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 RPN
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
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.

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.

Page 24