STEP 1:  

Review the process

STEP 2:  Brainstorm potential failure modes

1. The potential failure modes can be the following:

2. A Sputtering Engine
3. Poor Fuel Economy
4. Flat Tires
5. Expensive Brakes
6. Burnt Rubber/tire
7. Resale Value
8. Top Speed Is Impractical
9. Light doesn’t turn on
10. Light doesn’t turn off

Possible Root causes

 Light doesn’t turn on

11. Battery dead (8)
12. Broken wire (3)
13. Headlight out (10)
14. Switch corroded (2)
15. Switch broken (8)
16. Short circuit in switch (7)

STEP 3:  List potential effects of each failure

Possible failures

Light doesn’t turn on

 Driver can’t see obstacles (8)

17. Car inoperable at night (8)

Light doesn’t turn off

 Battery dies (8)

18. Car won’t start (10)

STEP 4:  Assign Severity rankings

1. Light doesn’t turn on

2. Driver can’t see obstacles (8)
3. Car inoperable at night (8)
4. Light doesn’t turn off
5. Battery dies (8)
6. Car won’t start (10)
7. Stops car journey, driver and passengers stranded (10)
 8. Driver rides less
Less Efficient (4)
9. Efficiency problem (3)
10. Stops car journey, driver and passengers stranded (10)
11. Driver would have to drive putting in consideration the fragility of top speed (3)
12. Car won’t start (8)

STEP 5:  Assign Occurrence rankings

1. Battery
dies. 1. Car stops
Engine stops (9)
2. Car drinks up too much fuel (5
3. Brakes corroding very much (5)
4. Puncture (3)
5. Car problem might go out of control (8)
6. Short circuit in switch/ Broken wire/ Corroded switch (7)

STEP 6:  Assign Detection rankings

1. Controls/indicators
2. Light deosn’t turn on
3. User notices lights on in dark
4. Different sound or unusual feel while driving (5)
5. Car fuel meter (2)
6. Having trouble while applying brakes (8)
7. Tire checks before journey. While driving, steering pulls to one side, excess noise (3)
8. Do prior homework/ Read the user manual (5)
9. User notices lights on in dark/Light doesn’t turn off (4)

STEP 7:  Calculate the RPN

Severity X

Failure A) Severity B) Probability C) Probabilit Risk

modes Rate 1- of y of preference
10 occurrence detection number
10=mos Rate 1-10 (RPN)
t severe Rate 1-10 10=lowest AxBxC
10= probability
highest
probability
Sputtering Stops car Car stops Different sound or 450
Engine journey, driver Engine stops (9) unusual feel while
and passengers driving (5)
stranded (10)
Poor Fuel Driver rides less Car drinks up too Car fuel meter (2) 40
Economy Less Efficient (4) much fuel (5)

Expensive Efficiency Brakes corroding Having trouble 120

Brakes problem (3) very much (5) while applying
brakes (8)
. Flat Tires/ Puncture (3) Tire checks before 60
Burnt Stops car journey. While
Rubber/tire journey, driver driving, steering
and passengers pulls to one side,
stranded (10) excess noise (3)
Top Speed Is Driver would Engine might stop Read the user 120
Impractical have to drive Car problem might manual
putting in go out of control Do prior
consideration (8) homework (5)
the fragility of
top speed (3)
Light doesn’t Battery dies. Broken wire User notices lights 224
turn off Car won’t start Corroded switch on in dark
(8) Broken switch Light doesn’t turn
Short circuit in off (4)
switch (7)