SEVERITY RANKING (SEV)

Score
10
9
8
7
6
5
4
3
2
1

Criteria
May endanger operator (machine or assembly) without warning
May endanger operator (machine or assembly) with warning
100% of product may have to be scrapped, line shut down, and stop shipment
A portion of the production run may have to be scrapped, decreased line speed, and added
manpower
100% of production may have to be reworked offline and accepted
A portion of the production may have to be reworked offline and accepted
100% of production may have to be reworked in-station before it is processed
A portion of production may have to be reworked in-station before it is processed
Slight inconvenience to process, operation or operator
No discernable effect

DETECTING USING CONTROLS (DET)

Score
10
9
8
7
6
5
4
3
2
1

Criteria
Cannot detect, no current process control
Failure mode and/or cause is not easily detected
Failure mode detection post process by operatorvisual/tactical/audible means
In-station by operatorvisual/tactile/audible, post process attribute gaging (go/no-go, etc)
Post process variable gaging, in-station attribute gaging
In-station variable gaging, automated controls in-station notification (buzzer), gaging on setup/
piece check
Post process detection by automated controls, and lock part to prevent further processing
In-station detection by automated controls, and lock part in-station to prevent further processin
In-station error (cause) detection by automated controls
In-station error (cause) prevention as a result of fixture design

OCCURRENCE OF CAUSE (OCC)

Score
10
9
8
7
6
5
4
3
2
1

Likelihood of Failure
Very High
High

Moderate
Low
Very Low

Occurrence of Cause
10%
5%
2%
1%
0.20%
0.05%
0.01%
0.00%
0.00%

Failure is eliminated through preventative con

y) without warning
y) with warning
e shut down, and stop shipment
e scrapped, decreased line speed, and added
offline and accepted
worked offline and accepted
in-station before it is processed
ed in-station before it is processed
operator

ed
torvisual/tactical/audible means
post process attribute gaging (go/no-go, etc)
ute gaging
in-station notification (buzzer), gaging on setup/first-

, and lock part to prevent further processing

d lock part in-station to prevent further processing
d controls
of fixture design

ccurrence of Cause
100 per thousand pieces
50 per thousand pieces
20 per thousand pieces
10 per thousand pieces
2 per thousand pieces
0.5 per thousand pieces
0.1 per thousand pieces
0.01 per thousand pieces
0.001 per thousand pieces
Failure is eliminated through preventative control