Process:

Prepared By:

Process Responsibility:

Item No. Process Function/Requirement

Failure Mode and Effects Analysis

Potential Failure Mode

System FMEA

C
S l
Potential Effect(s) of Failure e a
v s
s

10

2
 FMEA Reference Number:

Page: 1 of

FMEA Date (Orig): (Rev):

Current Process Controls

Potential Failure Cause

O
Prevention Controls c
c
10

2
rrent Process Controls R&D
Recommended
RPN Action
D
Detection Controls e Responsible
t
10 1000
0
0
4 64
0
0
2 8
0
0
0
0
0
0
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0
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 R&D Action Results

Action S O D
Target Completion Date s e c e RPN
Taken v c t
0
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 Failure Mode and Effects Analysis Design FMEA
FMEA Reference Number:
Process :
Page: 1 of
Prepared By:
FMEA Date (Orig): (Rev):
Process Responsibility :

C Current Process Controls R&D Action Results

S l
Item No. Process Function/Requirement Potential Failure Mode Potential Effect(s) of Failure e a Potential Failure Cause RPN Recommended
O D Action Action S O D
v s
s Prevention Controls c Detection Controls e Responsible Target Completion Date s e c e RPN
c t Taken v c t
10 10 10 1000 0
0 0
0 0
4 4 4 64 0
0 0
0 0
2 2 2 8 0
0 0
0 0
0 0
0 0
0 0
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 Failure Mode and Effects Analysis Process FMEA
FMEA Reference Number:
Process:
Page: 1 of
Prepared By:
FMEA Date (Orig): (Rev):
Process Responsibility:

C Current Process Controls R&D Action Results

S l Recommended
Process No. Process Function/Requirement Potential Failure Mode Potential Effect(s) of Failure e a Potential Failure Cause RPN Action
v s O D Action S O
s Prevention Controls c Detection Controls e Responsible Target Completion Date s e c
c t Taken v c
10 10 10 1000
 Failure Mode and Effects Analysis
Process:

Prepared By:

Process Responsibility:

Item No. Process Function/Requirement Potential Failure Mode

Machine FMEA
FMEA Reference Number:

Page: 1

FMEA Date (Orig):

Potential Effect(s) of Failure
C Current P
S l
e a Potential Failure Cause
v s
s Prevention Controls

10

2
 of

(Rev):

Current Process Controls R&D Action Results

RPN Recommended
O D Action Action S O D
c Detection Controls e Responsible Target Completion Date s e c e
c t Taken v c t
10 10 1000
0
0
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0
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0
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RPN

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 1 not perceptible
2 small
3 small
4 medium
5 medium
significance
6 medium
7 significant
8 significant
9 very significant
10 very significant
1 very probable
2 probable
3 medium
4 medium
5 medium
detection
6 small
7 small
8 small
9 very small
10 improbable
1 improbable
2 very small
3 very small
4 small
5 small
occurrence
6 small
7 medium
8 medium
9 high
10 high

1 None
2 Very Minor
3 Minor
4 Very Low
5 Low
significance
6 Moderate
7 High
8 Very High
9 Hazardous-with warning
10 Hazardous-without warning
1 Almost Certain
2 Very High
3 High
4 Moderately High
5 Moderate
detection
6 Low
7 Very Low
 detection

8 Remote
9 Very Remote
10 Absolute Uncertainty
1 Remote
2 Low
3 Low
4 Moderate
5 Moderate
occurrence
6 Moderate
7 High
8 High
9 Very High
10 Very High

1 None
2 Very Minor
3 Minor
4 Very Low
5 Low
significance
6 Moderate
7 High
8 Very High
9 Hazardous-with warning
10 Hazardous-without warning
1 Almost Certain
2 Very High
3 High
4 Moderately High
5 Moderate
detection
6 Low
7 Very Low
8 Remote
9 Very Remote
10 Almost impossible
1 Remote
2 Very Low
3 Low
4 Moderate
5 Moderate
occurrence
6 Moderate
7 High
8 High
9 Very High
10 Very High
 SYSTEM
not perceptible It is improbable that this failure will result in a perceptible change in the performance of the system. The
small This failure is not significant. The customer will not be inconvenienced by a the malfunction of the system.
small This failure is not significant. The customer will not be inconvenienced by a the malfunction of the system.
medium This failure is significant enough to inconvenience or angry the customer. He or she will notice the malfunction
medium This failure is significant enough to inconvenience or angry the customer. He or she will notice the malfunction
medium This failure is significant enough to inconvenience or angry the customer. He or she will notice the malfunction
significant Significant failure that causes a total malfunction of the system. The customer will not be able to use the system
significant Significant failure that causes a total malfunction of the system. The customer will not be able to use the system
very significant Significant failure that causes total inoperabilty of the system and possible malfunction of the safety mec
very significant Significant failure that causes total inoperabilty of the system and possible malfunction of the safety mec
very probable It is improbable that the failure will not be recognized during testing. Chance of discovery >= 99.99%
probable It is improbable that the failure will not be recognized during testing. Chance of discovery >= 99.7%
medium Chance of discovery >= 99.7%.
medium Chance of discovery >= 99.7%.
medium Chance of discovery >= 99.7%.
small Chance of discovery >= 98%.
small Chance of discovery >= 98%.
small Chance of discovery >= 98%.
very small Chance of discovery >= 90%
improbable Chance of discovery < 90%
improbable It is improbable for this failure to occur. Chance of failure <= 1/100000
very small This design is only slightly different from earlier proven designs. Chance of failure <= 1/20000
very small This design is only slightly different from earlier proven designs. Chance of failure <= 1/10000
small This design is only slightly different from earlier proven designs which failed in some cases. Chance of failure <=
small This design is only slightly different from earlier proven designs which failed in some cases. Chance of failure <=
small This design is only slightly different from earlier proven designs which failed in some cases. Chance of failure <=
medium This design is only slightly different from earlier proven designs which caused problems. Chance of failure <=
medium This design is only slightly different from earlier proven designs which caused problems. Chance of failure <=
high This design is almost certain to cause problems. Chance of failure <= 1/10
high This design is almost certain to cause problems. Chance of failure <= 1/2
DESIGN / MAC
No Effect
Fit & Finish/Squeak & Rattle item does not conform. Defect noticed by discriminating customer.
Minor Fit & Finish/Squeak & Rattle item does not conform. Defect noticed by average customer.
Very Low Fit & Finish/Squeak & Rattle item does not conform. Defect noticed by most customers.
Low Vehicle/item operable, but Comfort/Convenience item(s) operable at reduced level of performance. Customer experi
Moderate Vehicle/item operable, but Comfort/Convenience item(s) inoperable. Customer experiences discomfort.
High Vehicle/item operable, but at reduced level of performance. Customer dissatisfied.
Very High Vehicle/item inoperable, with loss of primary function.
Hazardous-with warning Very high severity ranking when a potential failure mode affects safe vehicle operation and/or in
Hazardous-without warning Very high severity ranking when a potential failure mode affects safe vehicle operation and/o
Almost Certain Design Control will almost certainly detect a potential cause/mechanism and subsequent failure mode.
Very High Very high chance the Design Control will detect a potential cause/mechanism and subsequent failure mode.
High High chance the Design Control will detect a potential cause/mechanism and subsequent failure mode.
Moderately High Moderately high chance the Design Control will detect a potential cause/mechanism and subsequent fail
Moderate Moderate chance the Design Control will detect a potential cause/mechanism and subsequent failure mode.
Low Low chance the Design Control will detect a potential cause/mechanism and subsequent failure mode.
Very Low Very low chance the Design Control will detect a potential cause/mechanism and subsequent failure mode.
Remote Remote chance the Design Control will detect a potential cause/mechanism and subsequent failure mode.
Very Remote Very remote chance the Design Control will detect a potential cause/mechanism and subsequent failure mod
Absolute Uncertainty Design Control will not and/or can not detect a potential cause/mechanism and subsequent failure m
Remote Failure is unlikely Possible Failure Rate <=1 in 1,500,000
Low Relatively few failures Possible Failure Rate 1 in 150,000
Low Relatively few failures Possible Failure Rate 1 in 15,000
Moderate Occasional failures Possible Failure Rate 1 in 2,000
Moderate Occasional failures Possible Failure Rate 1 in 400
Moderate Occasional failures Possible Failure Rate 1 in 80
High Repeated failures Possible Failure Rate 1 in 20
High Repeated failures Possible Failure Rate 1 in 8
Very High Failure is almost inevitable Possible Failure Rate 1 in 3
Very High Failure is almost inevitable Possible Failure Rate >=1 in 2
PROCESS
None No Effect.
Very Minor Minor disruption to production line. A portion (less than 100%) of the product may have to be reworked on-li
Minor Minor disruption to production line. A portion (less than 100%) of the product may have to be reworked on-line bu
Very Low Minor disruption to production line. The product may have to be sorted and a portion (less than 100%) reworke
Low Minor disruption to production line. 100% of product may have to be reworked. Fit & Finish/Squeak & Rattle item d
Moderate Minor disruption to production line. A portion (less than 100%) of the product may have to be scrapped (no sort
High Minor disruption to production line. Product may have to be sorted and a portion (less than 100%) scrapped. Vehic
Very High Major disruption to production line. 100% of product may have to be scrapped. Vehicle/item inoperable, loss
Hazardous-with warning May endanger machine of assembly operator. Very high severity ranking when a potential failur
Hazardous-without warning May endanger machine of assembly operator. Very high severity ranking when a potential fai
Almost Certain Design control(s) almost certain to detect the failure mode. Reliable detection controls are known wi
Very High Very high likelihood current control(s) will detect failure mode.
High High likelihood current control(s) will detect failure mode.
Moderately High Moderately high likelihood current control(s) will detect failure mode.
Moderate Moderate likelihood current control(s) will detect failure mode.
Low Low likelihood current control(s) will detect failure mode.
Very Low Very low likelihood current control(s) will detect failure mode.
Remote Remote likelihood current control(s) will detect failure mode.
Very Remote Very remote likelihood current control(s) will detect failure mode.
Almost impossible No known control(s) available to detect failure mode.
Remote Failure is unlikely. No failures ever associated with almost identical processes. Possible Failure Rate <
Very Low Only isolated failures associated with almost identical processes. Possible Failure Rate 1 in 150,000 Cpk >= 1
Low Isolated failures associated with similar processes. Possible Failure Rate 1 in 15,000 Cpk >= 1.33
Moderate Generally associated with processes similar to previous processes which have experienced occasional failures, b
Moderate Generally associated with processes similar to previous processes which have experienced occasional failures, b
Moderate Generally associated with processes similar to previous processes which have experienced occasional failures, b
High Generally associated with processes similar to previous processes that have often failed. Possible Failure Rate 1 in 2
High Generally associated with processes similar to previous processes that have often failed. Possible Failure Rate 1 in 8
Very High Failure is almost inevitable. Possible Failure Rate 1 in 3 Cpk >= 0.33
Very High Failure is almost inevitable. Possible Failure Rate >= 1 in 2 Cpk < 0.33