FMEA

ã Six Sigma Consultants, 1996
Failure Modes and Effects An

TM
FMEA Number:
Process Name:
Process Responsibility:
Prepared By:
Affected Product(s):
PFMEA Key Date:
FMEA Origination Date:
FMEA Revision Date:
Team Members:
PFMEA Information Sheet

lure Modes and Effects Analysis
PFMEA Information Sheet

C
Potential
Process Potential S l O Current D R Responsible S
Failure Modes Potential Causes Recommend Taken
# Function Failure Effects E a C Process E P Person & E
(process of Failure (KPIVs) Actions Actions
(Step) (KPOVs) V s C Controls T N Target Date V
defects)
s
1 0
2 0
3 0
4 0
5 0
6 0
7 0
8 0
9 0
10 0
11 0
12 0
13 0
14 0
15 0
16 0
17 0
18 0
FMEA Page 3
C
Potential
defects)
s
19 0
20 0
21 0
22 0
23 0
24 0
25 0
26 0
27 0
28 0
29 0
30 0
31 0
32 0
33 0
34 0
35 0
36 0
37 0
FMEA Page 4
C
Potential
defects)
s
38 0
39 0
40 0
41 0
42 0
43 0
44 0
45 0
46 0
47 0
48 0
49 0
50 0
FMEA Page 5
O D R
C E P
C T N
0 `
FMEA Page 6
O D R
C E P
C T N
FMEA Page 7
O D R
C E P
C T N
FMEA Page 8
Severity
Effect
Hazardous: Without Warning
Hazardous: With Warning
Very High
High
Moderate
Low
Very Low
Page 9
Severity
Minor
Very Minor
None
Page 10
Severity
Criteria: Severity of Effect Defined

May endanger operator. Failure mode affects safe vehicle operation and / or involves
noncompliance with government regulation. Failure will occur WITHOUT warning.
May endanger operator. Failure mode affects safe vehicle operation and / or involves
noncompliance with government regulation. Failure will occur WITH warning.
Major disruption to production line. 100% of product may have to be scrapped. Vehicle / item
inoperable, loss of primary function. Customer very dissatisfied.
Minor disruption to production line. Product may have to be sorted and a portion (less than 100%)
scrapped. Vehicle operable, but at a reduced level of performance. Customer dissatisfied.
Minor disruption to production line. A portion (less than 100%) may have to be scrapped (no
sorting). Vehicle / item operable, but some comfort / convenience item(s) inoperable. Customers
experience discomfort.
Minor disruption to production line. 100% of product may have to be reworked. Vehicle / item
operable, but some comfort / convenience item(s) operable at reduced level of performance.
Customer experiences some dissatisfaction.
Minor disruption to production line. The product may have to be sorted and a portion (less than
100%) reworked. Fit / finish / squeak / rattle item does not conform. Defect noticed by most
customers.
Page 11
Severity
Minor disruption to production line. A portion (less than 100%) of the product may have to be
reworked on-line but out-of-station. Fit / finish / squeak / rattle item does not conform. Defect
noticed by average customers.
Minor disruption to production line. A portion (less than 100%) of the product may have to be
reworked on-line but in-station. Fit / finish / squeak / rattle item does not conform. Defect noticed by
discriminating customers.
No effect.
Scale from AIAG FMEA-3:Potential Failure Effects Analysis Third Edition
Page 12
Severity
Ranking
10
Page 13
Severity
Page 14
Occurance
Probability of Failure
Very High:
Failure is almost inevitable

High: Generally associated with processes similar
to previous
processes that have often failed
Moderate: Generally associated with processes

similar to
previous processes which have
experienced occasional failures, but not in major

proportions
Low: Isolated failures associated with similar

processes
Very Low: Only isolated failures associated with

almost identical processes
Page 15
Occurance
Remote: Failure is unlikely. No failures ever

associated with almost identical processes
Scale from AIAG FMEA-3:Potential Failure Effects Analys
Page 16
Occurance
Possible Failure
Cpk Ranking
Rates
³ 1 in 2 < 0.33 10
1 in 3 ³ 0.33 9
1 in 8 ³ 0.51 8
1 in 20 ³ 0.67 7
1 in 80 ³ 0.83 6
1 in 400 ³ 1.00 5
1 in 2,000 ³ 1.17 4
1 in 15,000 ³ 1.33 3
1 in 150,000 ³ 1.5 2
Page 17
Occurance
£ 1 in 1,500,000 ³ 1.67 1
A-3:Potential Failure Effects Analysis Third Edition
Page 18
Detection
Detection
Almost Impossible
Very Remote
Remote
Very Low
Low
Moderate
Moderately High
High
Very High
Almost Certain
Scale from AIAG FMEA-3:Potential Failure Effects Analysis
Page 19
Detection
Criteria: Liklihood the existence of a defect will be

detected by test content before product advances to
next or subsequent process
No known control(s) available to detect failure mode
Test content must detect 60 % of failures

Test content must detect 99.5 % of failures
FMEA-3:Potential Failure Effects Analysis Third Edition
Page 20
Detection
Ranking
10
9
8
7
6
5
4
3
2
1
Page 21

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ã Six Sigma Consultants, 1996

Failure Modes and Effects An

PFMEA Key Date:

FMEA Origination Date:

FMEA Revision Date:

PFMEA Information Sheet

lure Modes and Effects Analysis

PFMEA Information Sheet

Hazardous: With Warning

Criteria: Severity of Effect Defined

Scale from AIAG FMEA-3:Potential Failure Effects Analysis Third Edition

Failure is almost inevitable

processes that have often failed

Moderate: Generally associated with processes

previous processes which have

experienced occasional failures, but not in major

Low: Isolated failures associated with similar

Very Low: Only isolated failures associated with

Remote: Failure is unlikely. No failures ever

Scale from AIAG FMEA-3:Potential Failure Effects Analys

A-3:Potential Failure Effects Analysis Third Edition

Scale from AIAG FMEA-3:Potential Failure Effects Analysis

Criteria: Liklihood the existence of a defect will be

Test content must detect 60 % of failures

FMEA-3:Potential Failure Effects Analysis Third Edition

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