Process FMEA

FMEA Instructions
1) Identify and name the process, product or service. Identify who has responsibility, and identify the team.
2) List the item functions in column A.
3) Identify possible failure modes in column B.
4) Describe potential effect(s) of failure modes in column C.
5) Use the provided table (in the Rating Factors Tab) to identify severity in column D.
6) Identify potential causes of failure in column E. Describe these in terms of something that can be corrected or can be controlled.
7) Rate the liklihood of the identified failure casue occurring in column F. Use the provided table in the Rating Factors Tab.
8) Describe the current process controls to prevent the failure mode in column G.
9) Use the provided table (in the Ratings Factors Tab) to determine the liklihood that that failure cause will be detected.
10) The Risk Priority Number will be calculated automatically.
11) Use the RPN to identify further actions in columns J, K, and L. Once action is taken, recalculate RPN.

Prepared by:
Item Name: FMEA Team:
FMEA Date (Orig): Revision #:

Potential Effect on S O D R S O D
Process Step or Variable or Future
Potential Failure Mode Customer Because of E Potential Causes C Current Process Controls E P Actions Recommended Resp.& Target Date Actions Taken E C E
Key Input RPN
Defect V C T N V C T

Future Occurance
What is the impact on

Future Detection
Risk Priority # to
How probable is
How frequent is

Future Severity
How Severe is

cause likely to
In what ways can the the Key Output Variables What are the existing What are the actions for reducing the What were the actions

Detection of
effect to the
What causes the Key

rank order
customer?

concerns
Process Step, Variable, (customer controls that either Occurrence of the cause, or Who's Responsible for implemented? Include

Occur?

cause?
What is the process Input to go wrong?
step? or Key Input go wrong? requirements) or (How could the failure prevent the failure mode improving Detection? Should the recommended completion month/year.
(chance of not meeting internal requirements if mode occur?) from occurring or detect have actions on high RPN's or action? What date? (Then recalculate
requirements) failure mode is not it should it occur? Severity of 9 or 10. resulting RPN.)
prevented or corrected ?

Spare tire and

Tire function: support Stops car journey, driver
weight of car, traction, Flat tire and passengers 10 Puncture 2 60 pulls Carry
Tire checks before journey. While 3driving, steering
spare tire and appropriate
to onetools
side,to
excess noise
Car owner appropriate tools 4 2 3 24
change tire From immediate effect permanently carried in
comfort stranded
trunk

All Rights Reserved, Juran Institute, Inc. Process Design and Process FMEA
 Process FMEA

FMEA Instructions
1) Identify and name the process, product or service. Identify who has responsibility, and identify the team.
2) List the item functions in column A.
3) Identify possible failure modes in column B.
4) Describe potential effect(s) of failure modes in column C.
5) Use the provided table (in the Rating Factors Tab) to identify severity in column D.
6) Identify potential causes of failure in column E. Describe these in terms of something that can be corrected or can be controlled.
7) Rate the liklihood of the identified failure casue occurring in column F. Use the provided table in the Rating Factors Tab.
8) Describe the current process controls to prevent the failure mode in column G.
9) Use the provided table (in the Ratings Factors Tab) to determine the liklihood that that failure cause will be detected.
10) The Risk Priority Number will be calculated automatically.
11) Use the RPN to identify further actions in columns J, K, and L. Once action is taken, recalculate RPN.

Prepared by:
Item Name: FMEA Team:
FMEA Date (Orig): Revision #:

Process Step or Variable Potential Effect on S O D R S O D Future

Potential Failure Mode Customer Because of E Potential Causes C Current Process Controls E P Actions Recommended Resp.& Target Date Actions Taken E C E
or Key Input Defect V C T N V C T RPN

How Severe is effect to

How frequent is cause

Risk Priority # to rank

Detection of cause?
What is the impact on What are the actions for

Future Occurance
Future Detection
How probable is

order concerns

Future Severity
likely to Occur?
In what ways can the the Key Output Variables the customer? reducing the Occurrence What were the actions
What causes the Key
Process Step, Variable, (customer What are the existing controls that of the cause, or Who's Responsible for implemented? Include
What is the process Input to go wrong?
or Key Input go wrong? requirements) or either prevent the failure mode from improving Detection? the recommended completion month/year.
step? (How could the failure
(chance of not meeting internal requirements if mode occur?) occurring or detect it should it occur? Should have actions on action? What date? (Then recalculate
requirements) failure mode is not high RPN's or Severity of resulting RPN.)
prevented or corrected ? 9 or 10.

Unauthorized cash
withdrawal Block ATM cards after three failed
Unauthorized access 8 Lost or stolen ATM card 3 3 72
Very dissatisified authentication attempts
customer

ATM PIN Authentication

Install load balancer to distribute

Authentication failure Annoyed customer 3 Network failure 5 5 75
work load across network links

Increase minimum cash

threshold limit of heavily
Cash not disburshed Dissatisfied customer 7 ATM out of cash 7 Internal alert of low cash in ATM 4 196 used ATM's to prevent
out of cash

Account debited but no Very dissatisfied Transaction failure Install load balancer to distribute
Dispense Cash cash disbursed customer 8 Network issue 3 work load across network links 4 96

Bills stuck to each other

Extra cash dispensed Bank loses money 8 2 Verification cash while loading 3 48
Bills stacked incorrectly

All Rights Reserved, Juran Institute, Inc. Process Design and Process FMEA
 Process FMEA

FMEA Instructions
1) Identify and name the process, product or service. Identify who has responsibility, and identify the team.
2) List the item functions in column A.
3) Identify possible failure modes in column B.
4) Describe potential effect(s) of failure modes in column C.
5) Use the provided table (in the Rating Factors Tab) to identify severity in column D.
6) Identify potential causes of failure in column E. Describe these in terms of something that can be corrected or can be controlled.
7) Rate the liklihood of the identified failure casue occurring in column F. Use the provided table in the Rating Factors Tab.
8) Describe the current process controls to prevent the failure mode in column G.
9) Use the provided table (in the Ratings Factors Tab) to determine the liklihood that that failure cause will be detected.
10) The Risk Priority Number will be calculated automatically.
11) Use the RPN to identify further actions in columns J, K, and L. Once action is taken, recalculate RPN.

Prepared by:
Item Name: FMEA Team:
FMEA Date (Orig): Revision #:

Potential Effect on S O D R S O D Futur

Process Step or Customer Because of E C Current Process E P Actions E C E e
Variable or Key Input Potential Failure Mode Potential Causes Controls Recommended Resp.& Target Date Actions Taken
Defect V C T N V C T RPN

What are the actions What were the

How probable is
How frequent is
What are the existing for reducing the

Future Severity
Risk Priority #
How Severe is

cause likely to

to rank order
In what ways can the actions

Detection of
effect to the

Occurance
What is the impact on the controls that either Occurrence of the Who's Responsible

customer?

Detection
concerns
Process Step, Variable, or What causes the Key Input to go implemented?

Occur?

cause?

Future
Future
What is the process Key Output Variables prevent the failure cause, or improving for the
step? Key Input go wrong? (customer requirements) wrong? (How could the failure mode from occurring Detection? recommended Include completion
(chance of not meeting mode occur?) month/year. (Then
requirements) or internal requirements? or detect it should it Should have actions action? What date? recalculate resulting
occur? on high RPN's or RPN.)
Severity of 9 or 10.

Agent may not understand

customer requirement due to 48
language barrier.
An FCR may not be  Call listening from
Flight Selection Agent system proficiency  provided, due to different 4 3 customer 4
profile & need of the perspective and
customer Agent may not come up with feedback
alternative but work on customer
assign way, Due to product
knowledge or updates.

• Agent fail to use all the • Customer may not get

tools and resources to FCR and will have to call
validate or obtain the back, increasing a • Periodic product
4 • Product Knowledge test
information before dissatisfaction with
delivering  United

• Agent took a longer time • Customer may end up

to find out correct
information due to
Utilizing tools and inappropriate system
resources
proficiency 
getting wrong
• Updated information issue • Daily Huddle
information , which will
impact travel experience  6 4 96

• Lack of system
proficiency will have
• Agent failed to check all impact on time taken on • Coaching and
the options available before delivery, which has a • System proficiency  feedback
coming to an conclusion 
financial loss for the
company 

• Self-made information

All Rights Reserved, Juran Institute, Inc. Process Design and Process FMEA
 Process FMEA

FMEA Instructions
1) Identify and name the process, product or service. Identify who has responsibility, and identify the team.
2) List the item functions in column A.
3) Identify possible failure modes in column B.
4) Describe potential effect(s) of failure modes in column C.
5) Use the provided table (in the Rating Factors Tab) to identify severity in column D.
6) Identify potential causes of failure in column E. Describe these in terms of something that can be corrected or can be controlled.
7) Rate the liklihood of the identified failure casue occurring in column F. Use the provided table in the Rating Factors Tab.
8) Describe the current process controls to prevent the failure mode in column G.
9) Use the provided table (in the Ratings Factors Tab) to determine the liklihood that that failure cause will be detected.
10) The Risk Priority Number will be calculated automatically.
11) Use the RPN to identify further actions in columns J, K, and L. Once action is taken, recalculate RPN.

Prepared by:
Item Name: FMEA Team:
FMEA Date (Orig): Revision #:

Potential Effect on S O D R S O D
Process Step or Variable or Future
Potential Failure Mode Customer Because of E Potential Causes C Current Process Controls E P Actions Recommended Resp.& Target Date Actions Taken E C E
Key Input RPN
Defect V C T N V C T

cause likely to Occur?

How Severe is effect

rank order concerns

Detection of cause?

Future Occurance
What are the actions for

Risk Priority # to
to the customer?

Future Detection
How probable is
How frequent is

Future Severity
What are the existing What were the actions
In what ways can the Process What is the impact on the reducing the Occurrence of
What causes the Key Input controls that either prevent Who's Responsible for the implemented? Include
Step, Variable, or Key Input Key Output Variables the cause, or improving
What is the process step? to go wrong? (How could the failure mode from recommended action? What completion month/year.
go wrong? (chance of not (customer requirements) or Detection? Should
the failure mode occur?) occurring or detect it should date? (Then recalculate resulting
meeting requirements) internal requirements? have actions on high RPN's
it occur? RPN.)
or Severity of 9 or 10.

All Rights Reserved, Juran Institute, Inc. Process Design and Process FMEA
RPN VALUE RISK CATEOGARY
1-50 Very Low
51-100 Low
101-150 Medium
151-200 High
201-250(>250) Very High
RISK CONTROL
Accept
accept
Avoid
Mitigate
Mitigate
 Design and Process FMEA Rating Factors

RATING DEGREE OF SEVERITY PROBABILITY OF OCCURRENCE ABILITY TO DETECT

FREQUENCY Detection
Sev Prob
( 1 in … ) Certainty
Customer will not notice the adverse Likelihood of Sure that the potential failure will be
1 effect or it is insignificant occurrence is remote 1,000,000 found or prevented before reaching the 100%
next customer
Customer will probably experience Low failure rate with Almost certain that the potential failure
2 slight annoyance supporting 20,000 will be found or prevented before 99%
documentation reaching the next customer
Customer will experience annoyance Low failure rate Low likelihood that the potential failure
3 due to the slight degradation of without supporting 5,000 will reach the next customer undetected 95
performance documentation
Customer dissatisfaction due to reduced Occasional failures Controls may detect or prevent the
4 performance 2,000 potential failure from reaching the next 90
customer
Customer is made uncomfortable or Relatively moderate Moderate likelihood that the potential
their productivity is reduced by the failure rate with failure will reach the next customer
5 500 85
continued degradation of the effect supporting
documentation
Warranty repair or significant Moderate failure rate Controls are unlikely to detect or
manufacturing or assembly complaint without supporting prevent the potential failure from
6 100 80
documentation reaching the next customer

High degree of customer dissatisfaction Relatively high failure Poor likelihood that the potential failure
due to component failure without rate with supporting will be detected or prevented before
7 complete loss of function. Productivity documentation 50 reaching the next customer 70
impacted by high scrap or rework levels.

Very high degree of dissatisfaction due High failure rate Very poor likelihood that the potential
to the loss of function without a without supporting failure will be detected or prevented
8 20 60
negative impact on safety or documentation before reaching the next customer
governmental regulations
Customer endangered due to the Failure is almost Current controls probably will not even
adverse effect on safe system certain based on detect the potential failure
9 performance with warning before failure warranty data or 10 50
or violation of governmental regulations significant Design
Verification* testing
Customer endangered due to the Assured of failure Absolute certainty that the current
adverse effect on safe system based on warranty controls will not detect the potential
10 performance without warning before data or significant 2 failure < 50
failure or violation of governmental Design Verification*
regulations testing

*Design Verification Testing (DVT): Test conducted when designing new products/services to verify that the optimal process design performs at the
level specified by customer requirements (CTQs). DVT is a methodical approach used to identify and resolve problems before finalizing the process
for new products/services.

All Rights Reserved, Juran Institute, Inc. Rating Factors Design and Process FMEA
 Design FMEA

FMEA Instructions
1) Identify and name the process, product or service. Identify who has responsibility, and identify the team.
2) List the item functions in column A.
3) Identify possible failure modes in column B.
4) Describe potential effect(s) of failure modes in column C.
5) Use the provided table (in the Rating Factors Tab) to identify severity in column D.
6) Identify potential causes of failure in column E. Describe these in terms of something that can be corrected or can be controlled.
7) Rate the liklihood of the identified failure casue occurring in column F. Use the provided table in the Rating Factors Tab.
8) Describe the current process controls to prevent the failure mode in column G.
9) Use the provided table (in the Ratings Factors Tab) to determine the liklihood that that failure cause will be detected.
10) The Risk Priority Number will be calculated automatically.
11) Use the RPN to identify further actions in columns J, K, and L. Once action is taken, recalculate RPN.

Prepared by:
Item Name: FMEA Team:
FMEA Date (Orig): Revision #:

Potential Effect on S O D R S O D
Future
Item Function Potential Failure Mode Customer Because of E Potential Causes C Current Process Controls E P Actions Recommended Resp.& Target Date Actions Taken E C E
RPN
Defect V C T N V C T
F
u

cause likely to Occur?

How Severe is effect

rank order concerns

Detection of cause?

Future Occurance
What are the Existing What are the actions for

Risk Priority # to
to the customer?

Future Detection
t

How probable is
How frequent is

In what ways can the
What is the component, Component, Subsystem or
function, or feature? System potentially fail to
meet the Design Intent ?
Future Severity
What were the actions
What is the impact on the Controls & Procedures (Fail- reducing the Occurrence of u
List every conceivable failure Who's Responsible for the implemented? Include
Key Output Variables Safe, Tests, the cause, or improving r
and/or failure mechanism recommended action? What completion month/year.
(customer requirements) or Mathemat.Calcs)that prevent Detection? Should have e
for each failure mode date? (Then recalculate resulting
internal requirements? either the cause or the actions on high RPN's or
RPN.) R
failure mode EASY FIXES
P
N

All Rights Reserved, Juran Institute, Inc. Process Design and Process FMEA