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Six Sigma Consultants, 1996
PFMEA Information Sheet
Failure Mo
FMEA Number:
Process Name:
Process Responsibility:
Prepared By:
Affected Product(s):
PFMEA Key Date:
FMEA Origination Date:
FMEA Revision Date:
Team Members:
TM
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Six Sigma Consultants
FMEA
# C l a s s
1 0
2 0
3 0
4 0
5 0
6 0
7 0
8 0
9 0
10 011 0
12 0
13 0
14 0
15 0
16 0
17 0
ProcessFunction
(Step)
PotentialFailureModes
(processdefects)
PotentialFailureEffects
(KPOVs)
SEV
PotentialCauses of
Failure(KPIVs)
OCC
CurrentProcessControls
DET
RPN
Recommend Actions
ResponsPerso
Target D
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Six Sigma Consultants
FMEA
# C l a s sProcess
Function(Step)
PotentialFailureModes
(processdefects)
PotentialFailureEffects
(KPOVs)
SEV
PotentialCauses of
Failure(KPIVs)
OCC
CurrentProcessControls
DET
RPN
Recommend Actions
ResponsPerso
Target D
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
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Six Sigma Consultants
FMEA
0
0
0
0
0
0
0
0
0
00 `
0
0
0
0
0
0
TakenActions
SEV
OCC
DET
RPN
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Six Sigma Consultants
FMEA
TakenActions
SEV
OCC
DET
RPN
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
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Six Sigma Consultants
FMEA
TakenActions
SEV
OCC
DET
RPN
0
0
0
0
0
0
0
0
0
0
0
0
0
0
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Severity
Page 9
Effect
Hazardous: Without Warning
Hazardous: With Warning
Very High
High
Moderate
Low
Very Low
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Severity
Page 10
Minor
Very Minor
None
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Severity
Page 11
Criteria: Severity of Effect DefinedMay endanger operator. Failure mode affects safe vehicle operation and / or involvesnoncompliance with government regulation. Failure will occur WITHOUT warning.
May endanger operator. Failure mode affects safe vehicle operation and / or involvesnoncompliance with government regulation. Failure will occur WITH warning.Major disruption to production line. 100% of product may have to be scrapped. Vehicle / iteminoperable, 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 (nosorting). Vehicle / item operable, but some comfort / convenience item(s) inoperable. Customersexperience discomfort.
Minor disruption to production line. 100% of product may have to be reworked. Vehicle / itemoperable, 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 than100%) reworked. Fit / finish / squeak / rattle item does not conform. Defect noticed by mostcustomers.
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Severity
Page 13
Ranking
10
9
8
7
6
5
4
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Occurance
Page 15
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Occurance
Page 16
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Occurance
Page 17
Probability of Failure
Very High:
Failure is almost inevitable
processes that have often failed
previous processes which have
High: Generally associated with processes similar to previous
Moderate: Generally associated with processessimilar to
experienced occasional failures, but not in major proportions
Low: Isolated failures associated with similar processes
Very Low: Only isolated failures associated withalmost identical processes
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Occurance
Page 19
Cpk Ranking
< 0.33 10
1 in 3 9
1 in 8 8
1 in 20 7
1 in 80 6
1 in 400 5
1 in 2,000 4
1 in 15,000 3
1 in 150,000 2
Possible FailureRates
1 in 2
0.33
0.51
0.67
0.83
1.00
1.17
1.33
1.5
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Occurance
Page 20
1
tial Failure Effects Analysis Third Edition
1 in 1,500,000 1.67
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Detection
Page 21
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Detection
Page 23
No known control(s) available to detect failure mode
Test content must detect 60 % of failures
Test content must detect 65 % of failuresTest content must detect 70 % of failuresTest content must detect 75 % of failuresTest content must detect 80 % of failuresTest content must detect 85 % of failuresTest content must detect 90 % of failures
Test content must detect 95 % of failuresTest content must detect 99.5 % of failures
-3:Potential Failure Effects Analysis Third Edition
Criteria: Liklihood the existence of a defect will bedetected by test content before product advances to
next or subsequent process
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Detection
Ranking
10
9
876543
21