Print # Item:

(example for training)

Rev.

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA) Process Responsibility: Key Date Vehicle Owner N/A

FMEA Number: Prepared by: Date (Orig.) Date (Rev.)

1000 Mike Walton 3/1/2010 N/A

Action Results Actions Taken N/A S e v N/A

Filling car with gasoline at gas station N/A

Model Year(s)/Vehicle(s) Core Team:

Process Function/ Requirements Potential Failure Mode

Potential Effect(s) of Failure Owner will have to ask for assistance at the gas station or call for help (a fairly minor situation severity is set low at 3)

S e v
3

Open Gas Door to Vehicle owner cannot find Access Gas Cap (this is lever to release door the first step in filling the gas tank)

C l a s s Minor

Potential Causes(s)/ Mechanism(s) of Failure Vehicle owner not familiar with gas door release levers and does not have access to owner's manual (this is a fairly rare situation - most vehicle owners can find the release lever, so the rate of Occurrence for this situation is set at a low value of 2)

O Current D c Process e c Controls t u -Prevention e r -Detection c 2 No controls around owner 10 awareness / training verification (practically speaking, it is impossible to detect when a vehicle owner does not know where the gasdoor release lever is, so the detection value is at the maximum of 10)

R. P. N. 60

Recommended Action(s)

Responsibility & Target Completion Date

No action for now - N/A monitor service calls and add a visible, removable tag to gas door lever if complaints are significant

(other process steps would normally be inserted here, in the the sequence that they are carried out - we are only focusing on the first and last stetps for this example) Replace gas cap Owner forgets to replace Gas cap lost (the severity gas cap, set on verhicle of this effect is higher than roof when the owner cannot find the gas door lever, since in this case the customer may need to purchase another gas cap) 5 Moderate Human error (this situation is much more likely to happen than the owner not being able to find the gas door lever thus the Occurrence value is much higher) 7 Vehicle owner visually detects cap on roof or sees open gas door in side mirror prior to departing from gas station 5 175 Add strap to gas John Smith gap so it will never 6/1/2011 be detached from vehicle (in this case, the high RPN value warrants action) Strap implemented (here's what it's all about! Implementing countermeasures to reduce risks) 5

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Print # Item:

(example for training)

Rev.

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA) Process Responsibility: Key Date Vehicle Owner N/A

FMEA Number: Prepared by: Date (Orig.) Date (Rev.)

1000 Mike Walton 3/1/2010 N/A

Action Results Actions Taken S e v

Filling car with gasoline at gas station N/A

Model Year(s)/Vehicle(s) Core Team:

Process Function/ Requirements Potential Failure Mode

Potential Effect(s) of Failure

S e v

C l a s s

Potential Causes(s)/ Mechanism(s) of Failure

O c c u r

Current Process Controls -Prevention -Detection

D e t e c

R. P. N.

Recommended Action(s)

Responsibility & Target Completion Date

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1000 Mike Walton 3/1/2010 N/A

Action Results O D c e c t N/A N/A R. P. N. N/A

25

Page 3 of 4

1000 Mike Walton 3/1/2010 N/A

Action Results O c c D e t R. P. N.

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