SECTION ONE

Introduction
To

FAILURE MODE EFFECTS & ANALYSIS

FMEA

1.0

Definition, ur!o"e, #nd r#ctice"

FMEA$ A SYSTEMIZED GROUP OF ACTIVITIES DESIGNED TO 1. RECO%NI&E #nd E'ALUATE t(e OTENTIAL FAILURE of # RODUCT) ROCESS #nd it" EFFECTS *. IDENTIFY ACTIONS +,IC, COULD ELIMINATE or REDUCE t(e C,ANCE of OTENTIAL FAILURE OCCURRIN% -. DOCUMENT t(e ROCESS
1.1

DESI%N FMEA .DFMEA/ ROCESS FMEA . FMEA/

ARE ANALYTICAL TEC,NI0UES UTILI&ED 1Y DESI%N RES ONSI1LE EN%INEER)TEAM
OR

MANUFACTURIN% RES ONSI1LE EN%INEER)TEAM

THESE TOOLS ARE USED TO ASSURE THAT POTENTIAL PRODUCT FAILURE MODES And THEIR ASSOCIATED CAUSES HAVE BEEN CONSIDERED and ADDRESSED IN THE DESIGN OR MANAUFACTURING PROCESS

1.*

DFMEA
SU ORTS DESI%N ROCESS in REDUCIN% RIS2 of FAILURES 34

AIDING IN THE OBJECTIVE EVALUATION OF DESIGN REQUIREMENTS AND DESIGN ALTERNATIVES AIDING IN THE INITIAL DESIGN FOR MANUFACTURING AND ASSEMBLY INCREASING THE PROBABILITY THAT POTENTIAL FAILURE MODES AND THEIR EFFECTS ON SYSTEMS AND PRODUCT OPERATION HAVE BEEN CONSIDERED IN THE DESIGN & DEVELOPMENT PROCESS PROVIDING ADDITIONAL INFORMATION TO AID IN THE PLANNING OF EFFICIENT DESIGN TESTING AND PRODUCT DEVELOPMENT PROGRAMS
1.-

DFMEA
ALSO SU ORTS DESI%N ROCESS 14

DEVELOPING A LIST OF POTENTIAL FAILURE MODES RANKED ACCORDING TO THEIR EFFECT ON THE CUSTOMER, THUS ESTABLISHING A PRIORITY SYSTEM FOR DESIGN IMPROVEMENTS AND DEVELOPMENT TESTING PROVIDING AN OPEN ISSUE FORMAT FOR RECOMMENDING AND TRACKING RISK REDUCING ACTIONS PROVIDING FUTURE REFERENCE TO AID IN ANALY ING FIELD CONCERNS, EVALUATING DESIGN CHANGES AND DEVELOPING ADVANCED DESIGNS

1.5

FMEA
T,E ROCESS FMEA
IDENTIFIES POTENTIAL PRODUCT RELATED PROCESS FAILURE MODES ASSESSES THE POTENTIAL CUSTOMER EFFECTS OF THE FAILURES IDENTIFIES THE POTENTIAL MANUFACTURING OR ASSEMBLY PROCESS CAUSES AND IDENTIFIES PROCESS VARIABLES ON WHICH TO FOCUS CONTROLS FOR OCCURRENCE REDUCTION OR DETECTION OF THE FAILURE CONDITIONS DEVELOPS A RANKED LIST OF POTENTIAL FAILURE MODES, THUS ESTABLISHING A PRIORITY SYSTEM FOR CORRECTIVE ACTION CONSIDERATIONS DOCUMENTS THE RESULTS OF THE MANUFACTURING OR ASSEMBLY PROCESS

1.6

FMEA A

LICATIONS
IN

MANUFACTURIN% SETTIN%S
DFMEA
SHOULD BE INITIATED BEFORE OR AT DESIGN CONCEPT FINALIZATION SHOULD BE CONTINUALLY UPDATED AS CHANGES OCCUR OR ADDITIONAL INFORMATION IS OBTAINED THROUGHOUT THE PHASES OF PRODUCT DEVELOPMENT SHOULD BE FUNDAMENTALLY COMPLETED BEFORE THE DRAWINGS ARE RELEASED FOR TOOLING, OR OTHER MANUFACTURING NEEDS ADDRESSES THE DESIGN INTENT AND ASSUMES THE DESIGN WILL BE MANUFACTURED AND ASSEMBLED TO THIS INTENT DOES NOT RELY ON PROCESS CONTROLS TO OVERCOME POTENTIAL WEAKNESSES IN THE DESIGN, BUT IT DOES TAKE THE TECHNICAL AND PHYSICAL LIMITATIONS OF A MANUFACTURING OR ASSEMBLY PROCESS

INTO CONSIDERATION
1.7

FMEA A

LICATIONS
IN

MANUFACTURIN% SETTIN%S
FMEA
SHOULD TAKE INTO ACCOUNT ALL MANUFACTURING OPERATIONS, FROM INDIVIDUAL COMPONENTS TO ASSEMBLIES DOES NOT RELY ON PRODUCT DESIGN CHANGES TO OVERCOME WEAKNESSES IN THE PROCESS DOES TAKE INTO CONSIDERATION A PRODUCTS DESIGN CHARACTERISTICS RELATIVE TO THE PLANNED MANUFACTURING OR ASSEMBLY PROCESS ASSURES THAT, TO THE EXTENT POSSIBLE, THE RESULTING PRODUCT MEETS CUSTOMER NEEDS AND EXPECTATIONS

1.8

2EY RESOURCES NECESSARY TO CONDUCT SUCCESSFUL FMEA RO%RAMS

COMMITMENT OF TO MANA%EMENT 2NO+LED%EA1LE INDI'IDUALS, I.E. E9 ERTISE IN$ DESI%N MANUFACTURIN% ASSEM1LY SER'ICE 0UALITY RELIA1ILITY INDIVIDUALS ATTENTIVE TO FMEA TIMELINESS, I.E. ACHIEVE GREATEST VALUE: BEFORE A DESIGN OR PROCESS FAILURE MODE HAS BEEN UNKNOWINGLY DESIGNED INTO THE PRODUCT PEOPLE RESOURCES MAY BE INTERNAL OR EXTERNAL TO THE BUSINESS, OR A

COMBINATION THEREOF
1.:

FMEA AD'ANTA%ES .AND LIMITATIONS/

AD'ANTA%ES$
EN,ANCE DESI%N AND MANUFACTURIN% EFFICIENCIES ALLE'IATE LATE C,AN%E CRISES MINIMI&E E9 OSURE TO RODUCT FAILURES AU%MENT 1USINESS RECORDS IM RO'E ;1OTTOM LINE< RESULTS ADD TO CUSTOMER SATISFACTION

1.=

FMEA AD'ANTA%ES .AND LIMITATIONS/

LIMITATIONS>
EM LOYEE TRAININ% RE0UIREMENTS INITIAL IM ACT ON RODUCT AND MANUFACTURIN% SC,EDULES FINANCIAL IM ACT RE0UIRED TO U %RADE DESI%N, MANUFACTURIN%, AND ROCESS E0UI MENT AND TOOLS

>T(e"e LIMITATIONS "(ou?d 3e reco@niAed #nd tre#ted #" ;"(ort terB< #nd ;BiniB#?< interru!tion" to # 3u"ine"", #nd under"tood to u?tiB#te?4 offer d4n#Bic AD'ANTA%ESC

1.10

SECTION TWO

FMEA LAN
UTILI&IN% 2EY RODUCTION ROCESSES AND RODUCT E'ALUATION TOOLS

*.0

0UALITY MANA%EMENT ROCESS

RINCI LES DRI'IN% CUSTOMER SATISFACTION

TEAMWORK MANAGING PROCESSES STATISTICAL PROCESS CONTROL

*.1

FMEA RE0UIRES

TEAM+OR2

1UILD 0UALITY INTO EO LE T,ROU%,

TRAINING an COMMITTED LEADERSHIP

*.*

MANA%IN% ROCESSES
UTILI&E A STYLE OF MANA%EMENT T,AT IS ALSO EO LE ORIENTED IN CONTRAST TO ONE T,AT IS SOLELY ORIENTED TO+ARD RESULTS

ROCESSDORIENTED MANA%EMENT
SU ORT AND STIMULATE EFFORTS TO IM RO'E T,E +AY EM LOYEES DO EO1S REINFORCES ;LON% TERM< OUTLOO2

MANA%EMENT CRITERIA
DISCI LINE TIME MANA%EMENT

S2ILL DE'ELO MENT ARTICI ATION & IN'OL'EMENT MORALE COMMUNICATION

*.-

STATISTICAL ROCESS CONTROL

!SPC"
STATISTICAL TOOLS ARETO Di#@r#B"

CAUSEDANDDEFFECT Di#@r#B" ,ISTO%RAMS CONTROL C(#rt" SCATTER Di#@r#B"

 %RA ,S C,EC2S,EETS

*.5

ROCESS INCOR ORATION

A ROCESS INCLUDES SOME COM1INATION OF$

MET,ODS MATERIALS MAC,INES MAN O+ER EN'IRONMENT MEASUREMENT

T,ESE ARE INCOR ORATED TO COM LETE TAS2S, SUC, AS RODUCIN% A RODUCT OR

ERFORMIN% A SER'ICE. A ROCESS ,AS MEASURA1LE IN UTS AND OUT UTS.

*.6

FMEA ROEECTS SELECTION & UR OSE

TAN%I1LE EFFECTS
SUCCESSFUL DE'ELO MENT OF NE+ RODUCTS S,ORTENIN% OF RODUCT DE'ELO MENT TIME INCREASED MAR2ET S,ARE INCREASED SALES 'OLUME DE'ELO MENT OF NE+ MAR2ETS INCREASED RODUCTION 'OLUME

FE+ER ROCESSES IM RO'ED 0UALITY REDUCED DEFECT COSTS FE+ER CUSTOMER COM LAINTS

*.7

FMEA ROEECTS SELECTION & UR OSE

INTAN%I1LE EFFECTS
INCREASED 0UALITYDCONSCIOUSNESS AND RO1LEMDCONSCIOUSNESS MORE CONFIDENCE IN NE+ RODUCT DE'ELO MENT IM RO'ED STANDARDI&ATION

IM RO'ED 0UALITY OF +OR2 IM RO'ED INFORMATION FEED1AC2

*.8

FMEA ROEECT IM LEMENTATION

QUANTITATIVE METHODS
SE'ERITY RAN2IN% OCCURRENCE RAN2IN% DETECTION RAN2IN%

RIS2 RIORITY NUM1ER .R N/

*.:

FMEA ROEECT IM LEMENTATION

QUALITATIVE METHODS
SIMILAR AST E9 ERIENCES 1RAINSTORMIN% ANALYSIS CUSTOMER.S/ IN UT

FINANCIAL IM ACT

*.=

FAILURE MODE ERRORS DESCRI TIONS DESIGN

OTENTIAL FAILURE MODE CAN 1E DESCRI1ED AS T,E MANNER IN +,IC, A COM ONENT, SYSTEM, OR SU1SYSTEM COULD FAIL TO MEET T,E DESI%N INTENT.

T,ESE FAILURE MODES S,OULD 1E DESCRI1ED IN ; ,YSICAL< OR TEC,NICAL TERMS.

*.10

FAILURE MODE ERRORS DESCRI TIONS PROCESS

OTENTIAL FAILURE MODE IS DEFINED AS T,E MANNER IN +,IC, T,E ROCESS COULD FAIL TO MEET T,E RE0UIREMENTS OF T,E DESI%N INTENT. T,E FMEA TEAM S,OULD 1E A1LE TO OSE AND ANS+ER T,E FOLLO+IN% 0UESTIONS$

,O+ CAN T,E ROCESS) ART FAIL TO MEET S ECIFICATIONSF RE%ARDLESS OF EN%INEERIN% S ECIFICATIONS, +,AT +OULD A CUSTOMER .END USER, SU1SE0UENT O ERATIONS, OR SER'ICE/ CONSIDER O1EECTIONA1LEF

*.11

FAILURE MODE ERRORS E9AM LES

%ROUNDED S,ORT CIRCUITED O EN CIRCUITED CRAC2ED ,ANDLIN% DAMA%E DEFORMED 1ENT IM RO ER SETDU FRACTURED O9IDI&ED STIC2IN% 1URRED LEA2IN% LOOSENED TOOL +ORN DIRTY

THESE ARE SOME #TYPICAL$ FAILURE MODES. IT IS RECOMMENDED THAT A COMPARISON OF SIMILAR PROCESSES AND A REVIEW OF CUSTOMER !SUBSE%UENT OPERATION AND END USER" CONSIDERATIONS BE CONDUCTED.

*.1*

FAILURE MODE ERRORS PROBABILISTIC ERRORS

DEFINITION$ A RO1A1ILISTIC ERROR IS ONE T,AT CANNOT 1E REDICTED +IT, CERTAINTY. SAM LE RO1LEM T,E 'OLTA%ES OF 60 1ATTERIES OF T,E SAME TY E ,A'E A MEAN OF 1.6* 'OLTS AND A STANDARD DE'IATION OF 0.05 'OLT.

FIND T,E RO1A1LE ERROR OF T,E MEAN AND T,E 60G CONFIDENCE LIMITS. SOLUTION$ RO1A1LE ERROR OF T,E MEAN H 0.7856 x H 0.7856 N H 0.7856" ND1 H 0.7856.0.05 5=/ H 0.00-:6 'OLTS T,EN, 60G CONFIDENCE LIMITS ARE 1.6* I 0.00-:6 'OLTS
*.1-

FAILURE MODE TECHNICAL ANALYSIS

FAILURE MODE ANALYSIS AND CONTROL MUST 1E ASSI%NED TO AN INDI'IDUAL +,O OSSESSES T,E 1AC2%ROUND E9 ERIENCE AND NECESSARY S2ILLS TO

SUCCESSFULLY MANA%E T,E FMEA. T,IS INDI'IDUAL MAY 1E AN EM LOYEE OF T,E COM ANY OR A S ECIALIST T,AT IS EN%A%ED 1Y T,E COM ANY.

*.15

ROCESS RE'IE+ IN RACTICE

FAILURE MODE ERRORS INTRODUCE A RIS2 INTO A ROCESS .OR ROCESSES/. A CONTROL SYSTEM RO'IDES A MEANS OF ;CATC,IN%< AN ERROR 1EFORE ANY DAMA%E IS INCURRED.

E9AM LE$
TYPE OF ERROR DESCRIPTION InforB#tion '#?id#tion T(ere #re no c(ecJ" to OBi""ion c#tc( incorrect or

incoB!?ete inforB#tion iteB". An a &'n'()*a)'+, ,-a&./, 012/ 3, )4, .*10,(('n5 16 .2*04a(, 1* ,*( )4a) 012/ 100a('1na//7 *,(2/) 'n 'n01**,0) 1* ,*( 3,'n5 (,n) )1 )4, (2../',*!(". T4'( 012/ 3, )4, 0a(, '6 )4,*, a*, n1 04,08( 1n 1* ,*( 3,61*, )4,7 a*, (23&')), . S204 an ,**1* 012/ *,(2/) 'n an 'n01**,0) (4'.&,n) 16 511 (, an .a7&,n) 61* 2n ,('*, '),&(. In )4'( ,-a&./,, )4, .*,6,*a3/, 01n)*1/ (7(),& 912/ 3, 1n, )4a) 912/ &1*, *,a '/7 a((2*, 01**,0) .*,.a*a)'1n 16 .2*04a(, 1* ,*(. T*a'n'n5 16 ()a66 an ('&./'67'n5 .*10,(( (),.( a*, a*,a( )1 (2..1*) )4'( 51a/.
*.16

FLO+ C,ART ROCESS DIA%RAMMIN%

FLOW CHART FOR PURCHASING PROCEDURE

*.17

FMEA LAN
ON%OIN% E'ALUATORY ROCEDURES
T,E INDI'IDUAL RES ONSI1LE FOR DESI%N AND)OR ROCESS IS ACCOUNTA1LE FOR ASSURIN% T,AT ALL DFMEA AND)OR PFMEA ACTIONS RECOMMENDED ,A'E 1EEN

IM LEMENTED OR ADE0UATELY ADDRESSED. T,E FMEA IS A LI'IN% DOCUMENT AND S,OULD AL+AYS REFLECT T,E LATEST DESI%N LE'EL, AS +ELL AS T,E LATEST RELE'ANT ACTIONS, INCLUDIN% T,OSE OCCURRIN% AFTER T,E START OF RODUCTION O ERATIONS.

*.18

SECTION THREE

IB!?eBentin@ FMEA

-.0

IDENTIFYIN% OTENTIAL FAILURES

PRODUCT CONSIDERATIONS & PRODUCTION OPERATIONS

FAILURE MODES DEFINITION

ALL +AYS IN +,IC, A RODUCT .INCLUDIN% EAC, OF ITS S ECIFIC ARTS/ OR ROCESS CAN FAIL TO ERFORM ITS INTENDED FUNCTION. MORE T,AN ONE FAILURE MODE CAN E9IST FOR A %I'EN ART OR ROCESS. ALSO, SOME FAILURES MAY 1E %RADUAL AND)OR ARTIAL, +,EREAS OT,ERS MAY OCCUR IMMEDIATELY AND COM LETELY.

-.1

IDENTIFYIN% OTENTIAL FAILURES

USE of STATISTICAL TOOLS TY ES)DEFINITIONS

1.

ARETO Di#@r#B". C?#""if4 f#i?ure" #ccordin@ to c#u"e. T(e f#i?ure" #re di#@r#BBed #ccordin@ to !riorit4, u"in@ # 3#rD@r#!( forB#t, Kit( 100G indic#tin@ t(e tot#? #Bount of f#i?ure". C#u"eD#ndDEffect Di#@r#B". A?"o, JnoKn #" ;fi"(3one di#@r#B".< U"ed to #n#?4Ae t(e c(#r#cteri"tic" of # !roduct or !roce"" #nd t(e f#ctor" t(#t contri3ute to t(eB, #nd to !ro"!ectiLe f#i?ure". ,i"to@r#B". FreMuenc4 d#t# o3t#ined froB Be#"ureBent" di"!?#4 # !e#J #round # cert#in L#?ue. T(i" c#n 3e u"ed to deterBine !otenti#? f#i?ure" 34 c(ecJin@ di"!er"ion "(#!e, center L#?ue, #nd t(e n#ture of di"!er"eBent.
-.*

*.

-.

IDENTIFYIN% OTENTIAL FAILURES

USE of STATISTICAL TOOLS TY ES)DEFINITIONS

5.

Contro? C(#rt". SerLe to detect #3norB#? L#ri#tion". S#B!?e d#t# .definin@ !otenti#? f#i?ure"/ #re !?otted to eL#?u#te "itu#tion" #nd trend" in # !roce"". CoB!#ri"on" c#n 3e B#de #@#in"t reMuired contro? ?iBit". Sc#tter Di#@r#B". Corre"!ondin@ d#t# #re !?otted #nd t(e re?#tion 3etKeen t(e d#t# .#nd iB!#ct on !ro"!ectiLe f#i?ure"/ c#n 3e #n#?4Aed.

6.

BESIDES THESE ANALYTICAL !STATISTICAL" TOOLS, THERE CAN OFTEN BE MANAGEMENT SITUATIONS #HERE THE DATA NEEDED FOR PROBLEM SOLVING ARE NOT AVAILABLE$ NE# PRODUCT DEVELOPMENT IS AN E%AMPLE$ ANOTHER MAY BE DEVELOPING A NE# MANUFACTURING METHOD TO IMPROVE PRODUCTIVITY$ THESE SITUATIONS REQUIRE COLLABORATION AMONG PEOPLE FROM DIFFERENT DEPARTMENTS$
-.-

IDENTIFYIN% OTENTIAL FAILURES

ROS ECTI'E 0UESTIONS

FOLLO+IN% ARE RE RESENTATI'E 0UESTIONS TO CONSIDER IN SOME 1ASIC AREAS T,AT MAY RE0UIRE FMEA. T,IS IS

NOT ALL INCLUSI'E, 1UT E9AM LES TO E'ALUATE. A. MATERIAL :. A*, )4,*, an7 &'()a8,( 'n +1/2&,; <. A*, )4,*, an7 &'()a8,( 'n 5*a ,; =. A*, )4,*, '&.2*')',( &'-, 'n; >. I( )4, 'n+,n)1*7 /,+,/ a ,?2a),; @. I( )4,*, an7 9a(), 'n &a),*'a/; A. I( )4, 4an /'n5 a ,?2a),; B. I( )4, ?2a/')7 ()an a* a ,?2a),; 1. O ERATION MET,OD :. A*, )4, 91*8 ()an a* ( a ,?2a),; <. I( ') a (a6, &,)41 ; =. I( ') a &,)41 )4a) ,n(2*,( a 511 .*1 20); >. I( ') an ,66'0',n) &,)41 ; @. A*, )4, ),&.,*a)2*, an 42&' ')7 a ,?2a),; A. I( )4, /'54)'n5 a ,?2a),; B. I( )4,*, a ,?2a), 01n)a0) 9')4 )4, .*,+'12( an n,-) .*10,((,(;
-.5

IDENTIFYIN% OTENTIAL FAILURES

ROS ECTI'E 0UESTIONS

C. MAC,INE :. D1,( ') &,,) .*1 20)'1n *,?2'*,&,n)(; <. D1,( ') &,,) .*10,(( 0a.a3'/')',(; =. D1,( ') &,,) .*,0'('1n *,?2'*,&,n)(; >. I( )4, /a712) a ,?2a),; @. A*, )4,*, ,n1254 &a04'n,(C6a0'/')',(; A. I( ,+,*7)4'n5 'n 511 91*8'n5 1* ,*; B. I( 1.,*a)'1n ()1.., 16),n 3,0a2(, 16 &,04an'0a/ )*123/,; D. MAN O+ER .O ERATOR/ :. D1,( (C4, 61//19 ()an a* (; <. I( 4'(C4,* 91*8 ,66'0',n07 a00,.)a3/,; =. I( 4,C(4, *,(.1n('3/, !a0012n)a3/,"; >. I( 4,C(4, ?2a/'6', ; @. I( 4,C(4, ,-.,*',n0, ; A. I( 4,C(4, a(('5n, )1 )4, *'54) D13; B. D1,( 4,C(4, &a'n)a'n 511 42&an *,/a)'1n(;
-.6

EFFECT AND ANALYSIS MET,ODOLO%IES

Fa&'()* M+d*

E,,*-. S*/*)&.01 2324 Ca(5*5 O--())*n-*1 2324 C+n.)+'5 D*.*-.&+n1 2324 RPN 6 S*/*)&.0 % O--())*n-* % D*.*-.&+n 232,444
-.7

EFFECT AND ANALYSIS MET,ODOLO%IES DEFININ% FMEA TERMS

RISK PRIORITY NUMBER (RPN)

T(e RIS2 RIORITY NUM1ER .R N/ i" t(e !roduct of t(e SE'ERITY .S/, OCCURRENCE .O/, #nd DETECTION .D/ r#nJin@$ R N H .S/ N .O/ N .D/ T(e R N i" # Be#"ure of de !"# $! %. T(e R N i" #?"o u"ed to r#nJ order t(e &o#&e$# !# '$o&e e .e.@., in #reto f#"(ion/. T(e R N Ki?? 3e 3etKeen ;1< #nd ;1,000.< For (i@(er R N" t(e te#B Bu"t undert#Je effort" to reduce t(i" c#?cu?#ted ri"J t(rou@( correctiLe #ction."/.

-.8

EFFECT AND ANALYSIS MET,ODOLO%IES

DEFININ% FMEA TERMS SEVERITY (S) SE'ERITY .S/ i" #n #""e""Bent of t(e "eriou"ne"" of t(e effect of t(e !otenti#? f#i?ure Bode. SE'ERITY #!!?ie" to t(e effect on?4. A reduction in SE'ERITY r#nJin@ indeN c#n 3e effected on?4 t(rou@( # de"i@n c(#n@e. SE'ERITY i" e"tiB#ted on # ;1< to ;10< "c#?e.
-.:

EFFECT AND ANALYSIS MET,ODOLO%IES SEVERITY (S) E()*+),!o# C$!,e$!)

Effect
HaEa* 12(F 9')412) 9a*n'n5 HaEa* 12(F 9')4 9a*n'n5 V,*7 4'54 H'54 M1 ,*a), L19 V,*7 L19

Criteri#$ SE'ERITY of Effect

V,*7 4'54 (,+,*')7 *an8'n5 94,n a .1),n)'a/ 6a'/2*, &1 , a66,0)( (a6, 1.,*a)'1n an C1* 'n+1/+,( n1n01&./'an0, 9')4 *,52/a)'1n( 9')412) 9a*n'n5. V,*7 4'54 (,+,*')7 *an8'n5 94,n a .1),n)'a/ 6a'/2*, &1 , a66,0)( (a6, 1.,*a)'1n an C1* 'n+1/+,( n1n01&./'an0, 9')4 *,52/a)'1n( 9')4 9a*n'n5. P*1 20)C'),& 'n1.,*a3/,, 9')4 /1(( 16 .*'&a*7 62n0)'1n. P*1 20)C'),& 1.,*a3/,, 32) a) *, 20, /,+,/ 16 .,*61*&an0,. C2()1&,* '((a)'(6', . P*1 20)C'),& 1.,*a3/,, 32) &a7 0a2(, *,91*8C*,.a'* an C1* a&a5, )1 ,?2'.&,n). P*1 20)C'),& 1.,*a3/,, 32) &a7 0a2(, (/'54) 'n01n+,n',n0, )1 *,/a), 1.,*a)'1n(. P*1 20)C'),& 1.,*a3/,, 32) .1((,((,( (1&, ,6,0)( !a,()4,)'0 an 1)4,*9'(," n1)'0,a3/, )1 &1() 02()1&,*(. P*1 20)C'),& 1.,*a3/,, 32) &a7 .1((,(( (1&, ,6,0)( n1)'0,a3/, 37 '(0*'&'na)'n5 02()1&,*(. P*1 20)C'),& 1.,*a3/,, 32) '( 'n n1n01&./'an0, 9')4 01&.an7 .1/'07. N1 ,66,0).

R#nJin@
:G

I B A @ >

M'n1* V,*7 M'n1* N1n, NOTE$

= < :

M#Je "ure te#B BeB3er" #@ree on t(e criteri# for r#nJin@ "eLerit4 #nd #!!?4 t(eB con"i"tent?4. -.=

EFFECT AND ANALYSIS MET,ODOLO%IES DEFININ% FMEA TERMS OCCURRENCE (O) OCCURRENCE .O/ i" t(e ?iJe?i(ood t(#t # "!ecific c#u"e)Bec(#ni"B Ki?? occur. OCCURRENCE i" e"tiB#ted on # ;1< to ;10< "c#?e.

-.10

EFFECT AND ANALYSIS MET,ODOLO%IES

OCCURRENCE (O) E()*+),!o# C$!,e$!)
ro3#3i?it4 of F#i?ure V,*7 H'54: Fa'/2*, '( a/&1() 'n,+')a3/, H'54: R,.,a), Fa'/2*,( M1 ,*a),: O00a('1na/ Fa'/2*,( o""i3?e F#i?ure R#te" : 'n < : 'n = : 'n I : 'n <G : 'n IG : 'n >GG : 'n <,GGG L19: R,/a)'+,/7 F,9 Fa'/2*,( R,&1),: Fa'/2*, '( Un/'8,/7 : 'n :@,GGG : 'n :@G,GGG : 'n :,@GG,GGG R#nJin@ :G H I B A @ > = < :

NOTE$

T(e te#B "(ou?d #@ree on #n eL#?u#tion criteri# #nd r#nJin@ "4"teB, K(ic( i" con"i"tent, eLen if Bodified for indiLidu#? !roduct)!roce"" #n#?4"i".

-.11

EFFECT AND ANALYSIS MET,ODOLO%IES

DEFININ% FMEA TERMS DETECTION (D)

DETECTION .D/ i" #n #""e""Bent of t(e #3i?it4 of !ro!o"ed >t4!e .*/ current de"i@n contro?" to detect # !otenti#? c#u"e)Bec(#ni"B .de"i@n Ke#Jne""/, or t(e #3i?it4 of t(e !ro!o"ed Ot4!e .-/ current de"i@n contro?" to detect t(e "u3"eMuent f#i?ure Bode, 3efore t(e coB!onent, "u3"4"teB, or "4"teB i" re?e#"ed for !roduction. In order to #c(ieLe # ?oKer r#nJin@, @ener#??4 t(e !?#nned de"i@n contro? .e.@., !reLent#tiLe, L#?id#tion, #nd)or Lerific#tion #ctiLitie"/ (#" to 3e iB!roLed. DETECTION i" e"tiB#ted on # ;1< to ;10< "c#?e. >T4!e .*/ De"i@n Contro?"$ Detect t(e c#u"e)Bec(#ni"B or f#i?ure Bode)effect froB occurrin@, or reduce t(eir r#te of occurrence. OT4!e .-/ De"i@n Contro?"$ Detect t(e f#i?ure Bode.
-.1*

EFFECT AND ANALYSIS MET,ODOLO%IES DETECTION (D) E()*+),!o# C$!,e$!)

Detection
A3(1/2), Un0,*)a'n)7 V,*7 R,&1),

Criteri#$ LiJe?i(ood of DETECTION 34 De"i@n Contro?

D,('5n C1n)*1/ 9'// n1) an C1* 0an n1) ,),0) a .1),n)'a/ 0a2(,C&,04an'(& an (23(,?2,n) 6a'/2*, &1 ,J 1* )4,*, '( n1 D,('5n C1n)*1/. V,*7 *,&1), 04an0, )4, D,('5n C1n)*1/ 9'// ,),0) a .1),n)'a/ 0a2(,C&,04an'(& an (23(,?2,n) 6a'/2*, &1 ,. R,&1), 04an0, )4, D,('5n C1n)*1/ 9'// ,),0) a .1),n)'a/ 0a2(,C&,04an'(& an (23(,?2,n) 6a'/2*, &1 ,. V,*7 /19 04an0, )4, D,('5n C1n)*1/ 9'// ,),0) a .1),n)'a/ 0a2(,C&,04an'(& an (23(,?2,n) 6a'/2*, &1 ,. L19 04an0, )4, D,('5n C1n)*1/ 9'// ,),0) a .1),n)'a/ 0a2(,C&,04an'(& an (23(,?2,n) 6a'/2*, &1 ,. M1 ,*a), 04an0, )4, D,('5n C1n)*1/ 9'// ,),0) a .1),n)'a/ 0a2(,C&,04an'(& an (23(,?2,n) 6a'/2*, &1 ,. M1 ,*a),/7 4'54 04an0, )4, D,('5n C1n)*1/ 9'// ,),0) a .1),n)'a/ 0a2(,C&,04an'(& an (23(,?2,n) 6a'/2*, &1 ,. H'54 04an0, )4, D,('5n C1n)*1/ 9'// ,),0) a .1),n)'a/ 0a2(,C&,04an'(& an (23(,?2,n) 6a'/2*, &1 ,. V,*7 4'54 04an0, )4, D,('5n C1n)*1/ 9'// ,),0) a .1),n)'a/ 0a2(,C&,04an'(& an (23(,?2,n) 6a'/2*, &1 ,. D,('5n C1n)*1/ 9'// a/&1() 0,*)a'n/7 ,),0) a .1),n)'a/ 0a2(,C&,04an'(& an (23(,?2,n) 6a'/2*, &1 ,.

R#nJin@
:G

R,&1),

V,*7 L19

L19 M1 ,*a),

A @

M1 ,*a),/7 H'54 H'54 V,*7 H'54

>

= <

A/&1() C,*)a'n NOTE$

M#Je "ure te#B BeB3er" #@ree on t(e eL#?u#tion criteri# #nd r#nJin@ "4"teB, K(ic( i" con"i"tent, eLen if Bodified for indiLidu#? !roduct #n#?4"i" -.1-

IDENTIFYIN% AND ESTA1LIS,IN% A RO RIATE FMEA TEAM.S/ BASE CONSIDERATIONS

SELECT A 0UALIFIED TEAM LEADER COMMITTED TO S ECIFIC FMEA ROEECT SELECT 0UALIFIED TEAM MEM1ERS T,AT ARE MULTIFUNCTIONAL AND RELATED TO S ECIFIC FMEA ROEECT %I'E ROEECT LEADER AND TEAM MEM1ERS COM LETE AUTONOMY TO MANA%E S ECIFIC FMEA ROEECT
-.15

IDENTIFYIN% AND ESTA1LIS,IN% A RO RIATE FMEA TEAM.S/ -ADDITIONAL. CONSIDERATIONS

+,EN OSSI1LE, SELECT AT LEAST ONE, OR MORE, TEAM MEM1ERS +IT, RE'IOUS FMEA E9 ERIENCE RO'IDE NECESSARY TRAININ% TO FURT,ER STREN%T,EN TEAM MEM1ERSP S2ILLS

INCOR ORATE ;STANDARDI&ATION< MET,ODS TO O1TAIN O'ERALL 1ENEFIT OF %I'IN% CONTROL OF EAC, FMEA ROEECT TO T,E EO LE +,O 2NO+ IT 1EST

-.16

SECTION FOUR

FMEA DocuBent#tion

5.0

2EY DOCUMENTATION MET,ODS FOR FMEA

TEC,NI0UES
:. D102&,n) an Un ,*()an existing P*1 20)( an P*10,((,( K R,+',9 02**,n) DOCUMENTATION &,)41 ( 61* ,-'()'n5 P*1 20)( an P*10,((,(, 94,*, a../'0a3/, K E+a/2a), (200,((,(, 6a'/2*,(, an *,/,+an0, 16 existing DOCUMENTS

<. V'(2a/'E, 419 existing P*1 20)( an P*10,((,( 0an 3, '&.*1+, !1* 419 )4,(, (412/ 3, 04an5, " 2)'/'E'n5 FMEA &,)41 ( K DOCUMENT: R,6,*,n0, C1n)*1/ P/an 61*& 'n A..,n '-

=. C1n(' ,* B,n04&a*8'n5 !2n ,*()an 'n5 3,() .*a0)'0, 'n )4, *,/,+an) 'n 2()*7 1* (,0)1*" an 13)a'n 'n61*&a)'1n 94'04 012/ 3, 2(,62/ 61* P*1 20) an C1* P*10,(( '&.*1+,&,n)!(", 'n0/2 'n5 DOCUMENTATION P*10, 2*,(.........2n ,*()an )4, 0a2(,( an &a5n')2 , 16 .*13/,&( 9')4 ,-'()'n5 .*1 20)( an C1* .*10,((,(, (1 ,661*) '( 6102(, 94,*, ') '( &1() *,?2'*,

>. I&./,&,n) ./an)F9' , #()an a* 'E, $ 61*&( an &,)41 ( )1 a((2*, 01n('(),n07 61* FMEA DOCUMENTATION

@.

P*1+' , )*a'n'n5 'n DOCUMENTATION .*10, 2*,(

5.1

FMEA A

LICATIONS

EFFECTI'E DOCUMENTATION ROCEDURES

Reference De"i@n FMEA forB i" A!!endiN Q Fo??oKin@ i" # de"cri!tion of t(e c#te@orie" noted on t(e DFMEA forB$ 1. #rt N#Be)No. Enter t(e n#Be #nd nuB3er of t(e "4"teB, "u3"4"teB, or coB!onent 3ein@ #n#?4Aed.

*. De"i@n Re"!on"i3i?it4 Enter t(e ori@in#? eMui!Bent B#nuf#cturer .OEM/, de!#rtBent, #nd @rou!. A?"o, inc?ude t(e "u!!?ier n#Be if JnoKn. -. re!#red 34 Enter t(e n#Be, te?e!(one nuB3er, coB!#n4 of t(e indiLidu#? .en@ineer/ re"!on"i3?e for !re!#rin@ t(e DFMEA.

5. Cu"toBer)A!!?ic#tion Enter t(e n#Be of t(e cu"toBer .intern#?)eNtern#?/ K(o i" t(e reci!ient of t(e DFMEA #nd t(e #!!?ic#tion .of t(e de"i@n intent/.

5.*

FMEA A

LICATIONS

EFFECTI'E DOCUMENTATION ROCEDURES

6. 2e4 D#te Enter t(e initi#? DFMEA due d#te, K(ic( "(ou?d not eNceed t(e "c(edu?ed !roduction de"i@n re?e#"e d#te. 7. FMEA D#te .Ori@./ .ReL./ Enter t(e d#te t(e ori@in#? FMEA K#" coB!i?ed, #nd t(e ?#te"t reLi"ion d#te, K(en #!!?ic#3?e. 8. Core Te#B Li"t t(e n#Be" of t(e re"!on"i3?e indiLidu#?" #nd de!#rtBent" K(ic( (#Le t(e #ut(orit4 to identif4 #nd)or !erforB t#"J". .It i" recoBBended t(#t #?? te#B BeB3er" n#Be", de!#rtBent", te?e!(one nuB3er", #ddre""e", etc. 3e inc?uded on # di"tri3ution ?i"t./ :. FMEA NuB3er Enter t(e FMEA docuBent nuB3er, K(ic( B#4 3e u"ed for tr#cJin@. =. IteB)NuB3er Enter t(e n#Be #nd nuB3er of t(e iteB 3ein@ #n#?4Aed. U"e t(e noBenc?#ture #nd "(oK t(e de"i@n ?eLe? #" indic#ted on t(e en@ineerin@ dr#Kin@.

5.-

FMEA A
10.

LICATIONS

EFFECTI'E DOCUMENTATION ROCEDURES

otenti#? F#i?ure Mode otenti#? F#i?ure Mode i" defined #" t(e B#nner in K(ic( # coB!onent, "u3"4"teB, or "4"teB cou?d !otenti#??4 f#i? to Beet t(e de"i@n intent. T(e !otenti#? f#i?ure Bode B#4 #?"o 3e t(e c#u"e of # !otenti#? f#i?ure Bode in # (i@(er ?eLe? "u3"4"teB, or "4"teB, or 3e t(e effect of one in # ?oKer ?eLe? coB!onent. E#c( !otenti#? f#i?ure Bode for t(e !#rticu?#r iteB #nd iteB function "(ou?d 3e ?i"ted. T(e #""uB!tion i" B#de t(#t t(e f#i?ure cou?d occur, 3ut B#4 not nece""#ri?4 occur. .EN#B!?e$ Corroded 3#tter4 c#"e/ otenti#? Effect."/ of F#i?ure otenti#? Effect."/ of F#i?ure #re defined #" t(e effect" of t(e f#i?ure Bode on function", #" !erceiLed 34 t(e cu"toBer. De"cri3e t(e effect" of t(e f#i?ure in terB" of K(#t t(e cu"toBer Bi@(t notice or eN!erience, reBeB3erin@ t(#t t(e cu"toBer B#4 3e #n intern#? cu"toBer #" Ke?? #" t(e u?tiB#te end u"er. St#te c?e#r?4 if t(e function cou?d iB!#ct "#fet4 or noncoB!?i#nce to re@u?#tion". .EN#B!?e$ Deterior#ted ?ife of t(e 3#tter4 DD #?"o, IB!#ired o!er#tion of t(e 3#tter4/
5.5

11.

FMEA A

LICATIONS

EFFECTI'E DOCUMENTATION ROCEDURES

1*. SeLerit4 .S/ SeLerit4 i" #n #""e""Bent of t(e "eriou"ne"" of t(e effect of t(e !otenti#? f#i?ure Bode to t(e neNt coB!onent, "u3"4"teB, "4"teB, or cu"toBer if it occur". SeLerit4 #!!?ie" to t(e effect on?4. SeLerit4 "(ou?d 3e e"tiB#ted on # ;1< to ;10< "c#?e. 1-. C?#""ific#tion T(i" co?uBn i" intended to 3e u"ed to c?#""if4 #n4 "!eci#? !roduct c(#r#cteri"tic" .e.@., critic#?, Je4, B#Ror, "i@nific#nt/ for coB!onent", "u3"4"teB", or "4"teB" t(#t B#4 reMuire #ddition#? !roce"" contro?". 15. otenti#? C#u"e."/)Mec(#ni"B."/ of F#i?ure otenti#? c#u"e of f#i?ure i" defined #" #n indic#tion of # de"i@n Ke#Jne"", t(e con"eMuence of K(ic( i" t(e f#i?ure Bode. Li"t, to t(e eNtent !o""i3?e, eLer4 conceiL#3?e f#i?ure c#u"e #nd)or f#i?ure Bec(#ni"B for e#c( f#i?ure Bode. T4!ic#? f#i?ure c#u"e" B#4 inc?ude, 3ut #re not ?iBited to$ Incorrect B#teri#? "!ecifiedS In#deMu#te de"i@n ?ife #""uB!tionS In#deMu#te B#inten#nce in"truction", etc. T4!ic#? f#i?ure Bec(#ni"B" B#4 inc?ude, 3ut #re not ?iBited to$ Yie?dS F#ti@ueS M#teri#? in"t#3i?it4S +e#rS Corro"ion, etc.
5.6

FMEA A

LICATIONS

EFFECTI'E DOCUMENTATION ROCEDURES

16. Occurrence .O/ Occurrence i" t(e ?iJe?i(ood t(#t # "!ecific c#u"e)Bec(#ni"B Ki?? occur. T(e ?iJe?i(ood of occurrence r#nJin@ nuB3er (#" # Be#nin@ r#t(er t(#n # L#?ue. ReBoLin@ or contro??in@ one or Bore of t(e c#u"e")Bec(#ni"B" of t(e f#i?ure Bode t(rou@( # de"i@n c(#n@e i" t(e on?4 K#4 # reduction in t(e occurrence r#nJin@ c#n 3e effected. T(e ?iJe?i(ood of occurrence of !otenti#? f#i?ure c#u"e)Bec(#ni"B i" e"tiB#ted on # ;1< to ;10< "c#?e. 17. Current De"i@n Contro?" Li"t t(e !reLention, de"i@n L#?id#tion)Lerific#tion .D'/, or ot(er #ctiLitie" K(ic( Ki?? #""ure t(e de"i@n #deMu#c4 for t(e f#i?ure Bode #nd)or c#u"e)Bec(#ni"B under con"ider#tion. Current contro?", "uc( #" B#t(eB#tic#? "tudie", ?#3or#tor4 te"tin@, fe#"i3i?it4 reLieK", !rotot4!e te"t", etc. #re t(o"e t(#t (#Le 3een or #re 3ein@ u"ed Kit( t(e "#Be or "iBi?#r de"i@n". T(ere #re t(ree t4!e" of de"i@n contro?")fe#ture" to con"ider, t(o"e t(#t$ .1/ !reLent t(e c#u"e)Bec(#ni"B or f#i?ure Bode)effect froB occurrin@, or reduce t(eir r#te of occurrence, .*/ detect t(e c#u"e)Bec(#ni"B #nd ?e#d to correctiLe #ction", #nd .-/ detect t(e f#i?ure Bode.
5.7

FMEA A

LICATIONS

EFFECTI'E DOCUMENTATION ROCEDURES

18. Detection .D/ Detection i" #n #""e""Bent of t(e #3i?it4 of t(e !ro!o"ed t4!e .*/ current de"i@n contro?" to detect # !otenti#? c#u"e)Bec(#ni"B .de"i@n Ke#Jne""/, or t(e #3i?it4 of t(e !ro!o"ed t4!e .-/ current de"i@n contro?" to detect t(e "u3"eMuent f#i?ure Bode, 3efore t(e coB!onent, "u3"4"teB, or "4"teB i" re?e#"ed for !roduction. R#nJin@ i" on # "c#?e of ;1< to ;10< de!endent on t(e detection ?eLe?. 1:. Ri"J riorit4 NuB3er .R N/ T(e Ri"J riorit4 NuB3er i" t(e !roduct of t(e SeLerit4 .S/, Occurrence .O/, #nd Detection .D/ r#nJin@. T(e R N i" # Be#"ure of de"i@n ri"J #nd Ki?? coB!ute 3etKeen ;1< #nd ;1,000.< 1=. RecoBBended Action."/ +(en t(e f#i?ure Bode" (#Le 3een r#nJ ordered 34 R N, correctiLe #ction "(ou?d 3e fir"t directed #t t(e (i@(e"t r#nJed concern" #nd critic#? iteB". T(e intent of #n4 recoBBended #ction i" to reduce #n4 one or #?? of t(e occurrence, "eLerit4, #nd)or detection r#nJin@".
5.8

FMEA A

LICATIONS

EFFECTI'E DOCUMENTATION ROCEDURES

*0. Re"!on"i3i?it4 & T#r@et CoB!?etion D#te Enter t(e or@#niA#tion #nd indiLidu#? re"!on"i3?e for t(e recoBBended #ction #nd t(e t#r@et coB!?etion d#te. *1. Action" T#Jen After #n #ction (#" 3een iB!?eBented, enter # 3rief de"cri!tion of t(e #ctu#? #ction #nd effectiLe d#te. **. Re"u?tin@ R N After t(e correctiLe #ction."/ (#Le 3een identified, e"tiB#te #nd record t(e re"u?tin@ "eLerit4, occurrence, #nd detection r#nJin@". C#?cu?#te #nd record t(e re"u?tin@ R N. If no #ction."/ #re t#Jen, ?e#Le t(e ;Re"u?tin@ R N< #nd re?#ted r#nJin@ co?uBn" 3?#nJ. A?? re"u?tin@ R N" "(ou?d 3e reLieKed #nd if furt(er #ction i" con"idered nece""#r4, re!e#t "te!" 1= t(rou@( **.

5.:

FMEA A

LICATIONS

EFFECTI'E DOCUMENTATION ROCEDURES

Reference roce"" FMEA forB i" A!!endiN Q Fo??oKin@ i" # de"cri!tion of t(e c#te@orie" noted on t(e FMEA forB$ 1. *. roce"" Enter t(e n#Be of t(e !roce"" 3ein@ #n#?4Aed. roce"" Re"!on"i3i?it4 Enter t(e ori@in#? eMui!Bent B#nuf#cturer .OEM/, de!#rtBent, #nd @rou!. A?"o, inc?ude t(e "u!!?ier n#Be if JnoKn. re!#red 34 Enter t(e n#Be, te?e!(one nuB3er, coB!#n4 of t(e indiLidu#? .en@ineer/ re"!on"i3?e for !re!#rin@ t(e FMEA. #rt N#Be)No. Enter t(e n#Be #nd nuB3er of t(e "4"teB, "u3"4"teB, or coB!onent 3ein@ #n#?4Aed.

-.

5.

6. 2e4 D#te Enter t(e initi#? FMEA due d#te, K(ic( "(ou?d not eNceed t(e "c(edu?ed "t#rt of !roduction d#te.
5.=

FMEA A

LICATIONS

EFFECTI'E DOCUMENTATION ROCEDURES

7. FMEA D#te .Ori@./ .ReL./ Enter t(e d#te t(e ori@in#? FMEA K#" coB!i?ed, #nd t(e ?#te"t reLi"ion d#te, K(en #!!?ic#3?e. 8. Core Te#B Li"t t(e n#Be" of t(e re"!on"i3?e indiLidu#?" #nd de!#rtBent" K(ic( (#Le t(e #ut(orit4 to identif4 #nd)or !erforB t#"J". .It i" recoBBended t(#t #?? te#B BeB3er" n#Be", de!#rtBent", te?e!(one nuB3er", #ddre""e", etc. 3e inc?uded on # di"tri3ution ?i"t./ :. FMEA NuB3er Enter t(e FMEA docuBent nuB3er, K(ic( B#4 3e u"ed for tr#cJin@. =. roce"" Function)ReMuireBent" Enter # "iB!?e de"cri!tion of t(e !roce"" or o!er#tion 3ein@ #n#?4Aed .e.@., turnin@, dri??in@, t#!!in@, Ke?din@, #""eB3?in@/. Indic#te #" conci"e?4 #" !o""i3?e t(e !ur!o"e of t(e !roce"" or o!er#tion 3ein@ #n#?4Aed. +(ere t(e !roce"" inLo?Le" nuBerou" o!er#tion" .e.@. #""eB3?in@/ Kit( different !otenti#? Bode" of f#i?ure, it B#4 3e de"ir#3?e to ?i"t t(e o!er#tion" #" "e!#r#te !roce""e".
5.10

FMEA A
10.

LICATIONS

EFFECTI'E DOCUMENTATION ROCEDURES

otenti#? F#i?ure Mode otenti#? F#i?ure Mode i" defined #" t(e B#nner in K(ic( t(e !roce"" cou?d !otenti#??4 f#i? to Beet t(e !roce"" reMuireBent" #nd)or de"i@n intent. It i" # de"cri!tion of t(e nonD conforB#nce #t t(#t "!ecific o!er#tion. It c#n 3e # c#u"e #""oci#ted Kit( # !otenti#? f#i?ure Bode in # "u3"eMuent .doKn"tre#B/ o!er#tion or #n effect #""oci#ted Kit( # !otenti#? f#i?ure in # !reLiou" .u!"tre#B/ o!er#tion. ,oKeLer, in !re!#r#tion of t(e FMEA, t(e #""uB!tion "(ou?d 3e B#de t(#t t(e incoBin@ !#rt."/)B#teri#?."/ #re correct. Li"t e#c( !otenti#? f#i?ure Bode for t(e !#rticu?#r o!er#tion in terB" of # coB!onent, "u3"4"teB, "4"teB, or !roce"" c(#r#cteri"tic. T(e #""uB!tion i" B#de t(#t t(e f#i?ure cou?d occur, 3ut B#4 not nece""#ri?4 occur. otenti#? Effect."/ of F#i?ure otenti#? Effect."/ of F#i?ure #re defined #" t(e effect" of t(e f#i?ure Bode on cu"toBer."/. T(e cu"toBer."/ in t(i" conteNt cou?d 3e t(e neNt o!er#tion, "u3"eMuent o!er#tion" or ?oc#tion", or t(e end u"er. De"cri3e t(e effect" of t(e f#i?ure in terB" of K(#t t(e cu"toBer Bi@(t notice or eN!erience. .EN#B!?e$ Err#tic o!er#tion DD #?"o, oor #!!e#r#nce/
5.11

11.

FMEA A

LICATIONS

EFFECTI'E DOCUMENTATION ROCEDURES

1*. SeLerit4 .S/ SeLerit4 i" #n #""e""Bent of t(e "eriou"ne"" of t(e effect of t(e !otenti#? f#i?ure Bode to t(e cu"toBer."/. SeLerit4 #!!?ie" to t(e effect on?4. SeLerit4 "(ou?d 3e e"tiB#ted on # ;1< to ;10< "c#?e. 1-. C?#""ific#tion T(i" co?uBn i" intended to 3e u"ed to c?#""if4 #n4 "!eci#? !roce"" c(#r#cteri"tic" .e.@., critic#?, Je4, B#Ror, "i@nific#nt/ for coB!onent", "u3"4"teB", or "4"teB" t(#t B#4 reMuire #ddition#? !roce"" contro?". If # c?#""ific#tion i" identified in t(e FMEA, notif4 t(e de"i@n re"!on"i3?e en@ineer "ince t(i" B#4 #ffect t(e en@ineerin@ docuBent" concernin@ contro? iteB identific#tion. 15. otenti#? C#u"e."/)Mec(#ni"B."/ of F#i?ure otenti#? c#u"e of f#i?ure i" defined #" (oK t(e f#i?ure cou?d occur, de"cri3ed in terB" of "oBet(in@ t(#t c#n 3e corrected or c#n 3e contro??ed. Li"t, to t(e eNtent !o""i3?e, eLer4 conceiL#3?e f#i?ure c#u"e #""i@n#3?e to e#c( !otenti#? f#i?ure Bode. T4!ic#? f#i?ure c#u"e" B#4 inc?ude, 3ut #re not ?iBited to$ In#ccur#te @#u@in@S IB!ro!er (e#t tre#tin@ D tiBe, teB!er#tureS #rt Bi""in@ or Bi"?oc#ted.
5.1*

FMEA A

LICATIONS

EFFECTI'E DOCUMENTATION ROCEDURES

16. Occurrence .O/ Occurrence i" (oK freMuent?4 t(e "!ecific c#u"e)Bec(#ni"B i" !roRected to occur. T(e occurrence r#nJin@ nuB3er (#" # Be#nin@ r#t(er t(#n # L#?ue. On?4 occurrence" re"u?tin@ in t(e f#i?ure Bode "(ou?d 3e con"idered for t(i" r#nJin@S f#i?ure detectin@ Be#"ure" #re not con"idered (ere. T(e ?iJe?i(ood of occurrence of !otenti#? f#i?ure c#u"e)Bec(#ni"B i" e"tiB#ted on # ;1< to ;10< "c#?e. 17. Current roce"" Contro?" Current !roce"" contro?" #re de"cri!tion" of t(e contro?" t(#t eit(er !reLent to t(e eNtent !o""i3?e t(e f#i?ure Bode froB occurrin@ or detect t(e f#i?ure Bode "(ou?d it occur. T(e"e contro?" c#n 3e !roce"" contro?" "uc( #" fiNture errorD!roofin@ or St#ti"tic#? roce"" Contro? .S C/, or c#n 3e !o"tD!roce"" eL#?u#tion. T(e eL#?u#tion B#4 occur #t t(e "u3Rect o!er#tion or #t "u3"eMuent o!er#tion". T(ere #re t(ree t4!e" of !roce"" contro?")fe#ture" to con"iderS t(o"e t(#t$ .1/ !reLent t(e c#u"e)Bec(#ni"B or f#i?ure Bode)effect froB occurrin@, or reduce t(eir r#te of occurrence, .*/ detect t(e c#u"e)Bec(#ni"B #nd ?e#d to correctiLe #ction", #nd .-/ detect t(e f#i?ure Bode.
5.1-

FMEA A

LICATIONS

EFFECTI'E DOCUMENTATION ROCEDURES

18. Detection .D/ Detection i" #n #""e""Bent of t(e !ro3#3i?it4 t(#t t(e !ro!o"ed t4!e .*/ current !roce"" contro?" Ki?? detect # !otenti#? c#u"e)Bec(#ni"B .!roce"" Ke#Jne""/, or t(e !ro3#3i?it4 t(#t t(e !ro!o"ed t4!e .-/ !roce"" contro?" Ki?? detect t(e "u3"eMuent f#i?ure Bode, 3efore t(e !#rt or coB!onent ?e#Le" t(e B#nuf#cturin@ o!er#tion or #""eB3?4 ?oc#tion. R#nJin@ i" on # "c#?e of ;1< to ;10< de!endent on t(e detection ?eLe?. 1:. Ri"J riorit4 NuB3er .R N/ T(e Ri"J riorit4 NuB3er i" t(e !roduct of t(e SeLerit4 .S/, Occurrence .O/, #nd Detection .D/ r#nJin@. T(i" L#?ue "(ou?d 3e u"ed to r#nJ order t(e concern" in t(e !roce"" .e.@., in #reto f#"(ion. T(e R N Ki?? coB!ute 3etKeen ;1< #nd ;1,000.< 1=. RecoBBended Action."/ +(en t(e f#i?ure Bode" (#Le 3een r#nJ ordered 34 R N, correctiLe #ction "(ou?d 3e fir"t directed #t t(e (i@(e"t r#nJed concern" #nd critic#? iteB". T(e intent of #n4 recoBBended #ction i" to reduce #n4 one or #?? of t(e occurrence, "eLerit4, #nd)or detection r#nJin@".
5.15

FMEA A

LICATIONS

EFFECTI'E DOCUMENTATION ROCEDURES

*0. Re"!on"i3i?it4 & T#r@et CoB!?etion D#te Enter t(e or@#niA#tion #nd indiLidu#? re"!on"i3?e for t(e recoBBended #ction #nd t(e t#r@et coB!?etion d#te. *1. Action" T#Jen After #n #ction (#" 3een iB!?eBented, enter # 3rief de"cri!tion of t(e #ctu#? #ction #nd effectiLe d#te. **. Re"u?tin@ R N After t(e correctiLe #ction."/ (#Le 3een identified, e"tiB#te #nd record t(e re"u?tin@ "eLerit4, occurrence, #nd detection r#nJin@". C#?cu?#te #nd record t(e re"u?tin@ R N. If no #ction."/ #re t#Jen, ?e#Le t(e ;Re"u?tin@ R N< #nd re?#ted r#nJin@ co?uBn" 3?#nJ. A?? re"u?tin@ R N" "(ou?d 3e reLieKed #nd if furt(er #ction i" con"idered nece""#r4, re!e#t "te!" 1= t(rou@( **. Fo??oKDU!$ T(e !roce"" re"!on"i3?e en@ineer i" re"!on"i3?e for #""urin@ t(#t #?? #ction" recoBBended (#Le 3een iB!?eBented or #deMu#te?4 #ddre""ed. T(e FMEA i" # ?iLin@ docuBent #nd "(ou?d #?K#4" ref?ect t(e ?#te"t de"i@n)!roce"" ?eLe?, #" Ke?? #" t(e ?#te"t re?eL#nt #ction", inc?udin@ t(o"e occurrin@ #fter t(e "t#rt of !roduction.
5.16

SECTION FIVE

IB!roLe De"i@n & FMEA roRect SJi??"

S!ecific ;InD,ou"e< roduct or roduction O!er#tion

6.0

FMEA ;IND,OUSE< ROEECT

AN APPROACH TO BUSINESS MODELING

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6.1