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Vocabulary:
FAILURE MODE: How a part or process can fail to meet
specifications.
CAUSE: A deficiency that results in a failure mode
sources of variation
EFFECT: Impact on customer if the failure mode is not
prevented or corrected.
FMEA Standardized Rating System
1 < RPN = (Degree of Severity)*(Likelihood of Occurrence)*(Ability to Detect) < 1000
RATING DEGREE OF SEVERITY LIKELIHOOD OF ABILITY TO DETECT
OCCURRENCE
1 Customer will not notice the adverse effect or it is Likelihood of occurrence is Sure that the potential failure will be found or
insignificant. remote. prevented before reaching the next customer.
2 Customer will probably experience slight Low failure rate with Almost certain that the potential failure will be
annoyance. supporting documentation. found or prevented before reaching the next
customer.
3 Customer will experience annoyance due to slight Low failure rate without Low likelihood that the potential failure will
degradation of performance. supporting documentation. reach the next customer undetected.
4 Customer dissatisfaction due to reduced Occasional failures. Controls may not detect or prevent the potential
performance. failure from reaching the next customer.
5 Customer is made uncomfortable or their Relatively moderate failure Moderate likelihood that the potential failure will
productivity is reduced by the continued rate with supporting reach the next customer.
degradation of the effect. documentation.
6 Warranty repair or significant manufacturing or Moderate failure rate without Controls are unlikely to detect or prevent the
assembly complaint. supporting documentation. potential failure from reaching the next
customer.
7 High degree of customer dissatisfaction due to Relatively high failure rate Poor likelihood that the potential failure will be
component failure without complete loss of with supporting detected or prevented before reaching the next
function. Productivity impacted by high scrap or documentation. customer.
rework levels.
8 Very high degree of dissatisfaction due to the loss High failure rate without Very poor likelihood that the potential failure will
of function without a negative impact on safety or supporting documentation. be detected or prevented before reaching the
governmental regulations. next customer.
9 Customer endangered due to the adverse effect on Failure is almost certain based Current controls probably will not even detect
safe system performance with warning before on warranty data or significant the potential failure.
failure or violation of governmental regulations. DV testing.
10 Customer endangered due to the adverse effect on Assured of failure based on Absolute certainty that the current controls will
safe system performance without warning before warranty data or significant not detect the potential failure.
failure or violation of governmental regulations. DV testing
Failure Modes and Effects Analysis
(FMEA)
Process or
Prepared by: Page ____ of ____
Product Name:
H o w s e v e re is th e e ffe c t o n th e
H o w o fte n d o e s th e C a u s e o r
H o w w e ll c a n y o u d e te c t th e
C a u s e o r F a ilu re M o d e ?
F a ilu re M o d e o c c u r?
Process S O D R
Step/Part E C E P Actions
c u s to m e r?
C a lc u la te d
Number Potential Failure Mode Potential Failure Effects V Potential Causes C Current Controls T N Recommended Resp.
What are the In what ways can the What is the impact of the What are the causes of the What are the existing controls What are the actions Who is
process steps? process step go wrong? Failure Mode on the Failure Mode? and procedures that prevent the for reducing the responsible for
customer? Cause or Failure Mode? occurrence, the
decreasing severity or recommended
improving detection? action?
0
FAILURE MODES AND EFFECTS ANALYSIS (FMEA)
Preparation FMEA Process Improvement
Tip: Whether or not you have direct contact with an external customer,
your project must be customer-focused. Identify the customer of your
process and understand the pain they feel. This will help drive your
improvement efforts so that the customer feels the impact of Six Sigma.
a. Gage Variability:
Precision: Accuracy: Both: