Design FMEA

Severity

Severity is the rank associated with the most serious effect for a given failure mode.
A reduction in the severity ranking index can be effected only through a design change.
Severity should be estimated using the following table;

Effect Criteria: Severity of Effect Ranking

Hazardous Affects safe vehicles operation, involves non-complience 10
witj out with government regulation without warming
warming
Hazardous effects safe vehicle operation, involves non- complience 9
with warming with government regulation with warming
very high Vehicle / item inoperable (loss of primary function) 8
High Vehicle / item inoperable but with reduced performance. 7
Customer very dissatisfied
Moderate Vehicle / item operable but comfort item inoperable. 6
Customer very dissatisfied
Low Vehicle /item inoperable and comfort item operable. 5
Customer dissatisfied
Very low Fit & Finish does not conform.Defects noticed 4
by most customers>75%
Minor Fit & Finish does not conform.Defects noticed 3
by most customers>50%
Very Minor Fit & Finish does not conform.Defects noticed 2
by most customers>25%
None No effect 1

Occurrence:

Probability of Failure Possible Failure Rates Ranking

very high >/=10% 10

High
5% 9

High 2% 8
1% 7

Moderate 0.5% 6
0.2% 5
0.1% 4
Low 0.05% 3
0.01% 2
Remote </=0.001% 1
Detection

Detection Criteria:Likehood of detection by design control Ranking

Absolete Design control will not / cannot detect a cause/ 10
uncertainity Mechanism and subsequent failure mode : or
there is no design control.

Very remote Very remote chance the design control will detect a 9
potential cause/ mechanism and subsequent
failure mode
Remote Remote chance the design control will detect a 8
potential cause/ mechanism and subsequent
failure mode
Very Low Very low chance the design control will detect a
potential cause mechanism and subsequent failure mode. 7

Low Low chance the design control will detect a potential

cause/mechanism and subsequent failure mode. 6

Moderate Moderate chance the desgin control will detect a 5

potential cause / mechanism and subsequent failure
mode.
Moderatly High Moderately high chance the design control will detect 4
a potential cause/mechanism and subsequent failure
mode.
High High chance the design control will detect a potential 3
cause / mechanism and subseuent failure mode.
Very High Very high chance the design control will detect a 2
potential cause / mechanism and subsequent failure
Almost certain Design control will almost certainly detect a potential 1
cause / mechanism and subseuent failure mode.
PROCESS FMEA

Severity

Severity is the rank associated with the most serious effect for a given failure mode.
A reduction in the severity ranking index can be effected only through a design change
to system, sub system or component redesign of the process.

Effect Customer Effect Mfg./Assembly Effect Ranking

Hazardous Affects safe vehicles operation,or involves non-complience May endager operator, 10
with out with government regulation without warning operator, Machine or assembly
warning without warning.

Hazardous effects safe vehicle operation, involves non- complience May endager operator, 9
operator, Machine or assembly
with warning with government regulation with warning without warning.
very high Vehicle / item inoperable (loss of primary function) 100% scrap, repair time>one 8
hour
High Vehicle / item inoperable but with reduced performance. 100% Segregation & portion 7
scrap, repair time half an hour
Customer very dissatisfied to one hour
Moderate Vehicle / item operable but comfort item inoperable. Portion scraped without sorting 6
or repair time less than half an
Customer very dissatisfied hour
Low Vehicle /item inoperable and comfort item operable. 100% reworked or repaired off-line 5
not go to repair department
Customer dissatisfied
Very low Fit & Finish does not conform.Defects noticed Sorted no scrap and a portion 4
by most customers>75% reworked
Minor Fit & Finish does not conform.Defects noticed No scrap, Portion rework on line 3
but out of station
by most customers>50%
Very Minor Fit & Finish does not conform.Defects noticed No scrap, Portion rework online 2
but in station.
by most customers>25%
None No effect No effect 1

Occurrence:

Probability of Failure Possible Failure Rates Ranking

very high >/=10% 10

High
5% 9

High 2% 8
1% 7

Moderate 0.5% 6
0.2% 5
0.1% 4
Low 0.05% 3
0.01% 2
Remote </=0.001% 1
Detection

Detection Criteria:Likehood of detection by design control Ranking

Almost impossible Certain non-conformance 10

Very remote Very remote chance the design control will detect a 9
potential cause/ mechanism and subsequent
failure mode
Remote Remote chance the design control will detect a 8
potential cause/ mechanism and subsequent
failure mode
Very Low Very low chance the design control will detect a
potential cause mechanism and subsequent failure mode. 7

Low Low chance the design control will detect a potential

cause/mechanism and subsequent failure mode. 6

Moderate Moderate chance the desgin control will detect a 5

potential cause / mechanism and subsequent failure
mode.
Moderatly High Moderately high chance the design control will detect 4
a potential cause/mechanism and subsequent failure
mode.
High High chance the design control will detect a potential 3
cause / mechanism and subseuent failure mode.
Very High Very high chance the design control will detect a 2
potential cause / mechanism and subsequent failure
Almost certain Design control will almost certainly detect a potential 1
cause / mechanism and subseuent failure mode.
Detection

Detection Criteria:Likehood of detection by design control Type Detection Method

A B C
Almost impossible Certain non-conformance x Cannot detect or is not
checked
Very remote Controls will probably not detect x Indirect or random
checks only

Remote Controls have poor chance of detection x Visual inspection only

Very Low Controls have poor chance of detection x Double visual inspection
only

Low Control may detect x x SPC charting methods

Moderate Control may detect x Variable gauging or

100% Go/No Go after
parts left station
Moderatly High Controls have a good chance to detect x x Set-up and first-piece
check and subsquent
controls
High Controls have a good chance to detect x x cannot accept discrepant
part
Very High Controls almost certain to detect x x Cannot pass discrepant
part
Almost certain Controls certain to detect x cannot make discrepant
cause / mechanism and subseuent failure mode. part

Inspection types:

A : Error proofed/Mistake proofed/Poka-yoke

B : Gauging

C : Manual Inspection
Ranking

10