Sys

System

Subsystem

Component

Item:

Design Responsibility:

Model Year / Vehicle:

Key Date:

Item

Function

Failure Mode

Failure Effect

Severity

Core
team:

Potential Failure
Cause

System FMEA

nt

n Responsibility:

Prepared by:

ate:

Created:

RPN

Detection Action

Detection

Preventive
Action

Occurrence

Modified:

Recommended
Actions

Responsible
& Deadline

Actions Taken
RPN

Detection

Occurrence

Severity

Page:

Number:

Design FMEA
System

Subsystem

Page:

Component

Number:

Item:

Design Responsibility:

Prepared by:

Model Year / Vehicle:

Key Date:

Created:

Core
team:
Recommended
Actions

Responsible
& Deadline

Actions Taken

RPN

Detection
Action

Detection

Preventive
Action

Occurrence

Potential Failure
Cause

Severity

RPN

Failure Effect

Detection

Failure Mode

Occurrence

Function

Severity

Item

Modified:

Core team:

Key Date:

Modified:

Process
Step

Function

Failure Mode

Failure Effect

Potential Failure
Cause

Preventive
Action

Detection
Action

Recommended
Actions

Responsible
& Deadline

Actions Taken

RPN

Created:

Detection

Prepared by:

RPN

Product:

Detection

Number:

Occurrence

Responsibility:

Severity

FMEA:

Occurrence

Page:

Severity

Machine FMEA

Prepared by:

Core team:

Key Date:

Item

Function

Failure Mode

Failure Effect

Potential Failure
Cause

Preventive
Action

Detection
Action

RPN

Product:

Detection

Responsibility:

Severity

FMEA:

Occurrence

Machine FMEA

Recommended
Actions

Page:

Number:
Created:

RPN

Detection

Actions Taken

Occurrence

Responsible
& Deadline

Severity

Modified:

significance

detection

occurrence

1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10

not perceptible
small
small
medium
medium
medium
significant
significant
very significant
very significant
very probable
probable
medium
medium
medium
small
small
small
very small
improbable
improbable
very small
very small
small
small
small
medium
medium
high
high

DES

significance

detection

1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7

None
Very Minor
Minor
Very Low
Low
Moderate
High
Very High
Hazardous-with warnin
Hazardous-without war
Almost Certain
Very High
High
Moderately High
Moderate
Low
Very Low

detection

occurrence

significance

detection

occurrence

8
9
10
1
2
3
4
5
6
7
8
9
10

Remote
Very Remote
Absolute Uncertainty
Remote
Low
Low
Moderate
Moderate
Moderate
High
High
Very High
Very High

1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10

None
Very Minor
Minor
Very Low
Low
Moderate
High
Very High
Hazardous-with warnin
Hazardous-without war
Almost Certain
Very High
High
Moderately High
Moderate
Low
Very Low
Remote
Very Remote
Almost impossible
Remote
Very Low
Low
Moderate
Moderate
Moderate
High
High
Very High
Very High

SYSTEM
not perceptible It is improbable that this failure will result in a perceptible change in the perform
small This failure is not significant. The customer will not be inconvenienced by a the malfunction
small This failure is not significant. The customer will not be inconvenienced by a the malfunction
medium This failure is significant enough to inconvenience or angry the customer. He or she will
medium This failure is significant enough to inconvenience or angry the customer. He or she will
medium This failure is significant enough to inconvenience or angry the customer. He or she will
significant Significant failure that causes a total malfunction of the system. The customer will not
significant Significant failure that causes a total malfunction of the system. The customer will not
very significant Significant failure that causes total inoperabilty of the system and possible malfu
very significant Significant failure that causes total inoperabilty of the system and possible malfu
very probable It is improbable that the failure will not be recognized during testing. Chance of di
probable It is improbable that the failure will not be recognized during testing. Chance of discove
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 <=
very small This design is only slightly different from earlier proven designs. Chance of failure <=
small This design is only slightly different from earlier proven designs which failed in some cases
small This design is only slightly different from earlier proven designs which failed in some cases
small This design is only slightly different from earlier proven designs which failed in some cases
medium This design is only slightly different from earlier proven designs which caused problems
medium This design is only slightly different from earlier proven designs which caused problems
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 / MACHINE
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 perform
Moderate Vehicle/item operable, but Comfort/Convenience item(s) inoperable. Customer experien
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 veh
Hazardous-without warning Very high severity ranking when a potential failure mode affects safe
Almost Certain Design Control will almost certainly detect a potential cause/mechanism and subs
Very High Very high chance the Design Control will detect a potential cause/mechanism and subs
High High chance the Design Control will detect a potential cause/mechanism and subsequent fai
Moderately High Moderately high chance the Design Control will detect a potential cause/mechan
Moderate Moderate chance the Design Control will detect a potential cause/mechanism and subs
Low Low chance the Design Control will detect a potential cause/mechanism and subsequent failu
Very Low Very low chance the Design Control will detect a potential cause/mechanism and subseq

Remote Remote chance the Design Control will detect a potential cause/mechanism and subsequ
Very Remote Very remote chance the Design Control will detect a potential cause/mechanism and
Absolute Uncertainty Design Control will not and/or can not detect a potential cause/mechanism a
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 hav
Minor Minor disruption to production line. A portion (less than 100%) of the product may have to b
Very Low Minor disruption to production line. The product may have to be sorted and a portion (le
Low Minor disruption to production line. 100% of product may have to be reworked. Fit & Finish/Sq
Moderate Minor disruption to production line. A portion (less than 100%) of the product may have
High Minor disruption to production line. Product may have to be sorted and a portion (less than
Very High Major disruption to production line. 100% of product may have to be scrapped. Vehicle
Hazardous-with warning May endanger machine of assembly operator. Very high severity ranking
Hazardous-without warning May endanger machine of assembly operator. Very high severity rank
Almost Certain
Design control(s) almost certain to detect the failure mode. Reliable detectio
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.
Very Low Only isolated failures associated with almost identical processes. Possible Failure Rate 1
Low Isolated failures associated with similar processes. Possible Failure Rate 1 in 15,000 Cpk >=
Moderate Generally associated with processes similar to previous processes which have experien
Moderate Generally associated with processes similar to previous processes which have experien
Moderate Generally associated with processes similar to previous processes which have experien
High Generally associated with processes similar to previous processes that have often failed. Po
High Generally associated with processes similar to previous processes that have often failed. Po
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

his failure.

em are not impaired.

em are not impaired.

ment regulation with warning.

ernment regulation without warning.

& Rattle item does not conform. Defect noticed by discriminating customers.
& Rattle item does not conform. Defect noticed by average customers.
does not conform. Defect noticed by average customers.
verage customers.
me Comfort/Convenience item(s) inoperable. Customer experiences discomfort.
of performance. Customer dissatisfied.
dissatisfied.
n and/or involves noncompliance with government regulation. Failure will occur with warning.
ation and/or involves noncompliance with government regulation. Failure will occur without warning.

ble Failure Rate 1 in 2,000 Cpk >= 1.17

ble Failure Rate 1 in 400 Cpk >= 1.00
ble Failure Rate 1 in 80 Cpk >= 0.83

h warning.
without warning.