Criteria:
Effect Severity of Effect on Product Rank Effect
(Customer Effect)
Potential failure mode affects safe vehicle
operation and/or involves noncompliance
10
with government regulations without
Failure to Meet warning. Failure to Meet
Safety and/or Safety and/or
Regulatory Regulatory
Requirements Requirements
Potential failure mode affects safe vehicle
operation and/or involves noncompliance 9
with government regulations with warning.
Loss of primary function (vehicle inoperable, Major
8
does not effect safe vehicle opertaion). Discruption
Loss or
Degradation of
Primary Function
Degradation of primary function (vehicle
Significant
operable, but at reduced level of 7
Discruption
performance).
Loss of secondary function (vehicle operable,
but comfort/convenience functions 6
inoperable).
Loss or
Degradation of Moderate
Secondary Discruption
Function
Degradation of secondary function (vehicle
operable, but comfort/convenience functions 5
at reduced level of performance).
Appearance or Audible Noise, vehicle
operable, item does not conform and noticed 4
by most customers (75%).
Moderate
Discruption
Appearance or Audible Noise, vehicle
Annoyance operable, item does not conform and noticed 3
by many customers (50%).
Appearance or Audible Noise, vehicle
Minor
operable, item does not conform and noticed 2
Discruption
by discriminating customers (<25%).
No eefect No discernible effect. 1 Not efefct
Criteria:
Severity of Effect on Product
(Manufacturing/Assembly Effect)
May endanger operator (machine or
assembly) without warning.
May endanger operator (machine or
assembly) with warning.
100% of product may have to be scrapped.
Line shutdown or stop ship.
A portion of the production run may have to
be scrapped. Deviation from primary process
including decreased libe speed or added
manpower.
100% of production run may have to be
reworked off line and accepted.
A portion of the production run may have to
be reworked off line and accepted.
100% of production run may have to be
reworked in station before it is processed.
A portion of the production run may have to
be reworked in-station before it is processed.
Slight inconvenience to process, operation,
or operator.
No discernible effect.
Likelihood of Criteria: Occurrence of Cause - PFMEA
Failure (Incidents per items/vehicles)
³ 100 per thousand
Very High
³ 1 in 10
50 per thousand
1 in 20
20 per thousand
High
1 in 50
10 per thousand
1 in 100
2 per thousand
1 in 500
.5 per thousand
Moderate
1 in 2,000
.1 per thousand
1 in 10,000
.01 per thousand
1 in 100,000
Low
³ 0.001 per thousand
1 in 1,000,000
Very Low Failure is eliminated through preventive control
Rank
10
1
Criteria:
Opportunity for
Detection
Likelihood of Detection by Process Control
No detection
No current process control; Cannot detect or is not analyzed.
opportunity
Not likely to detect at
Failure Mode and/or Error (Cause) is not easily detected (e.g., random audits).
any stage
Problem Detection Failure Mode detection post-processing by operator through
Post Processing visual/tactile/audible means.
Failure Mode detection at-station by operator through visual/tactile/audible
Problem Detection at
means or post-processing through use of attribute gauging (go/no-go, manual
Source
toque check/clicker wrench, etc).
Failure Mode detection post-processing by operator through use variable
Problem Detetcion
gauging or in-station by operator through use of attribute gauging (go/no-go,
Post Processing
manual toque check/clicker wrench, etc).
Failure Mode or Error (Cause) detection in-stationby operator through use
Problem Detection at variable gauging or by automated control in-station that will detect discrepant
Source part and notify operator (light, busser, tec.). Gauging performed on setup and
first-piece check (for set-up causes only).
Failure Mode detection post-processing by automated controls that will detect
Problem Detection
discrepant part and automatically lock part in station to prevent further
Post Processing
processing.
Problem Detection at Failure Mode detection in-station by automated controls that will detect
Source discrepant part and automatically lock part in station to prevent further
processing.
Error Detection
Error (Cause) detection in-station by automated controls that will detect error
and/or Problem
and prevent discrepant part from being made.
Prevention
Detection not Error (Cause) prevention as a result of fixture design, machine design or part
applicable; Error design. Discrepant parts cannot be made because item has been error-proofed
Prevention by process/product design.
Rank
Likelihood of
Detection
Almost
10 Impossible
9 Very Remote
8 Remote
7 Very Low
6 Low
5 Moderate
4 Moderate
High
3 High
2 Very High
Almost
1 Certain
