© Six Sigma Consultants, 1996

 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

Potential
Potential Potential
Process Failure S O Current D R Responsible
Class
Failure Causes of Recomme
# Function Modes E C Process E P Person &
Effects Failure nd Actions
(Step) (process V C Controls T N Target Date
(KPOVs) (KPIVs)
defects)
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
FMEA Page 3
Potential
Potential Potential
Class
(KPOVs) (KPIVs)
defects)
18 0
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
FMEA Page 4
Potential
Potential Potential
Class
(KPOVs) (KPIVs)
defects)
37 0
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
S O D R
Taken
E C E P
Actions
V C T N
0 `
FMEA Page 6
S O D R
Taken
E C E P
Actions
V C T N
FMEA Page 7
S O D R
Taken
E C E P
Actions
V 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
Page 15
Occurance
Page 16
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 17
Occurance
Remote: Failure is unlikely. No failures ever

associated with almost identical processes
Scale from AIAG FMEA-3:Potential Failure Effects Analys
Page 18
Occurance
Possible Failure
Cpk Ranking
Rates
≥ 1 in 2 < 0.33 10
1 in 3 ≥ 0.33 9
1 in 8 ≥ 0.51 8
1 in 20 ≥ 0.67 7
1 in 80 ≥ 0.83 6
1 in 400 ≥ 1.00 5
1 in 2,000 ≥ 1.17 4
1 in 15,000 ≥ 1.33 3
1 in 150,000 ≥ 1.5 2
Page 19
Occurance
≤ 1 in 1,500,000 ≥ 1.67 1
A-3:Potential Failure Effects Analysis Third Edition
Page 20
Detection
Page 21
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 22
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 23
Detection
Ranking
10
9
8
7
6
5
4
3
2
1
Page 24

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© Six Sigma Consultants, 1996

Uploaded by

Copyright:

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 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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