System FMEA

System Subsystem Component

Item: Design Responsibility:

Model Year / Vehicle: Key Date:

Item Function Failure Mode Failure Effect

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Potential Failure Cause

System FMEA

Component

Design Responsibility: Prepared by:

Key Date: Created:

Modified:

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Design FMEA Page:

System Subsystem Component Number:

Item: Design Responsibility: Prepared by:

Model Year / Vehicle: Key Date: Created:

Modified:

Item Function Failure Mode Failure Effect

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Core team:

Potential Failure Cause

Recommended Actions

Responsible & Deadline

Machine FMEA Page:

FMEA: Responsibility: Number:

Product: Prepared by: Created:

Core team: Key Date: Modified:

Function Failure Mode Failure Effect

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Potential Failure Cause

Recommended Actions

Responsible & Deadline

Machine FMEA

FMEA: Responsibility:

Product: Prepared by:

Core team: Key Date:

Item Function Failure Mode Failure Effect

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Recommended Actions

Machine FMEA Page:

Responsibility: Number:

Prepared by: Created:

Key Date: Modified:

Actions Taken

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SYSTEM

significance

1 not perceptible2 small3 small

4 medium

5 medium

6 medium

7 significant

8 significant9 very significant

10 very significant

detection

1 very probable2 probable3 medium4 medium5 medium6 small7 small8 small9 very small

10 improbable

occurrence

1 improbable2 very small3 very small4 small5 small6 small7 medium8 medium9 high

10 highDESIGN / MACHINE

significance

1 None2 Very Minor3 Minor4 Very Low

5 Low6 Moderate7 High8 Very High

9 Hazardous-with warning

significance

10 Hazardous-without warning

detection

1 Almost Certain2 Very High3 High4 Moderately High5 Moderate6 Low7 Very Low8 Remote9 Very Remote

10 Absolute Uncertainty

occurrence

1 Remote2 Low3 Low4 Moderate5 Moderate6 Moderate7 High8 High9 Very High

10 Very HighPROCESS

significance

1 None

2 Very Minor

3 Minor

4 Very Low

5 Low

6 Moderate

7 High

8 Very High

9 Hazardous-with warning

10 Hazardous-without warning

detection

1 Almost Certain2 Very High3 High4 Moderately High5 Moderate

detection6 Low7 Very Low8 Remote9 Very Remote

10 Almost impossible

occurrence

1 Remote2 Very Low3 Low

4 Moderate

5 Moderate

6 Moderate

7 High

8 High9 Very High

10 Very High

SYSTEM

not perceptible It is improbable that this failure will result in a perceptible change in the performance of the system. The customer is not likely to notice this failure. small This failure is not significant. The customer will not be inconvenienced by a the malfunction of the system. small This failure is not significant. The customer will not be inconvenienced by a the malfunction of the system.

medium This failure is significant enough to inconvenience or angry the customer. He or she will notice the malfunctioning of the system.

medium This failure is significant enough to inconvenience or angry the customer. He or she will notice the malfunctioning of the system.

medium This failure is significant enough to inconvenience or angry the customer. He or she will notice the malfunctioning of the system.

significant Significant failure that causes a total malfunction of the system. The customer will not be able to use the system. Safety mechanisms of the system are not impaired.

significant Significant failure that causes a total malfunction of the system. The customer will not be able to use the system. Safety mechanisms of the system are not impaired. very significant Significant failure that causes total inoperabilty of the system and possible malfunction of the safety mechanisms. very significant Significant failure that causes total inoperabilty of the system and possible malfunction of the safety mechanisms. very probable It is improbable that the failure will not be recognized during testing. Chance of discovery >= 99.99% probable It is improbable that the failure will not be recognized during testing. Chance of discovery >= 99.7% 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 <= 1/20000 very small This design is only slightly different from earlier proven designs. Chance of failure <= 1/10000 small This design is only slightly different from earlier proven designs which failed in some cases. Chance of failure <= 1/2000 small This design is only slightly different from earlier proven designs which failed in some cases. Chance of failure <= 1/1000 small This design is only slightly different from earlier proven designs which failed in some cases. Chance of failure <= 1/200 medium This design is only slightly different from earlier proven designs which caused problems. Chance of failure <= 1/100 medium This design is only slightly different from earlier proven designs which caused problems. Chance of failure <= 1/20 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 / MACHINENo EffectFit & 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 performance. Customer experiences some dissatisfaction.Moderate Vehicle/item operable, but Comfort/Convenience item(s) inoperable. Customer experiences discomfort.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 vehicle operation and/or involves noncompliance with government regulation with warning.

Almost Certain Design Control will almost certainly detect a potential cause/mechanism and subsequent failure mode. Very High Very high chance the Design Control will detect a potential cause/mechanism and subsequent failure mode.High High chance the Design Control will detect a potential cause/mechanism and subsequent failure mode.Moderately High Moderately high chance the Design Control will detect a potential cause/mechanism and subsequent failure mode. Moderate Moderate chance the Design Control will detect a potential cause/mechanism and subsequent failure mode. Low Low chance the Design Control will detect a 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. Remote Remote chance the Design Control will detect a potential cause/mechanism and subsequent failure mode. Very Remote Very remote chance the Design Control will detect a potential cause/mechanism and subsequent failure mode.

Absolute Uncertainty Design Control will not and/or can not detect a potential cause/mechanism and subsequent failure mode; or there is no Design Control. 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

PROCESSNone No Effect.

Low Minor disruption to production line. 100% of product may have to be reworked. Fit & Finish/Squeak & Rattle item does not conform. Defect noticed by average customers.

Very High Major disruption to production line. 100% of product may have to be scrapped. Vehicle/item inoperable, loss of primary function. Customer very dissatisfied.

Almost Certain Design control(s) almost certain to detect the failure mode. Reliable detection controls are known with similar processes. 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.

Hazardous-without warning Very high severity ranking when a potential failure mode affects safe vehicle operation and/or involves noncompliance with government regulation without warning.

Very Minor 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.

Minor 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.

Very Low 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 average customers.

Moderate Minor disruption to production line. A portion (less than 100%) of the product may have to be scrapped (no sorting). Vehicle/item operable, but some Comfort/Convenience item(s) inoperable. Customer experiences discomfort.

High 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.

Hazardous-with warning May endanger machine of assembly operator. Very high severity ranking when a potential failure mode affects safe vehicle operation and/or involves noncompliance with government regulation. Failure will occur with warning.

Hazardous-without warning May endanger machine of assembly operator. Very high severity ranking when a potential failure mode affects safe vehicle operation and/or involves noncompliance with government regulation. Failure will occur without warning.

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. Possible Failure Rate <=1 in 1,500,000 Cpk >= 1.67 Very Low Only isolated failures associated with almost identical processes. Possible Failure Rate 1 in 150,000 Cpk >= 1.50 Low Isolated failures associated with similar processes. Possible Failure Rate 1 in 15,000 Cpk >= 1.33

High Generally associated with processes similar to previous processes that have often failed. Possible Failure Rate 1 in 20 Cpk >= 0.67

High Generally associated with processes similar to previous processes that have often failed. Possible Failure Rate 1 in 8 Cpk >= 0.51 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

Moderate Generally associated with processes similar to previous processes which have experienced occasional failures, but not in major proportions. Possible Failure Rate 1 in 2,000 Cpk >= 1.17

Moderate Generally associated with processes similar to previous processes which have experienced occasional failures, but not in major proportions. Possible Failure Rate 1 in 400 Cpk >= 1.00

Moderate Generally associated with processes similar to previous processes which have experienced occasional failures, but not in major proportions. Possible Failure Rate 1 in 80 Cpk >= 0.83