Design FMEA

Design Team: Date:

Product:

Item or Potential Potential S Potential O Design D RPN Recommended

Function Failure Effect(s) Cause(s) Controls Actions
Mode

Definitions for the FMEA Form

Item/Function:
Function is defined as the action the system or component is
designed to perform.

Examples include:
Position/locate Retain/attach/secure
Support/reinforce Lubricate
Seal in/out Isolate
Protect/shield Transfer/transport
Vent Provide signal
Potential Failure Mode:
Failure mode is the manner in which a system, subsystem, or
component could potentially fail to meet the design requirements.

Examples include:
Cracked Loosened Leaking
Deformed Worn Sticking
Fractured Binding Slipping

Potential Effect(s) of the Failure:

Potential effect(s) of the failure is defined as the consequence of
the failure as perceived by the customer.

Examples include:
Noise Poor appearance Poor fit
Loss of power Odor Loss of function
No output Excess friction Erratic operation
Loss of fluid Seizure Deterioration of
neighboring
component

Severity (S):
Severity is defined as an assessment of the seriousness of the
failure on the system performance.

Rank each effect:

1 - Minor effect on system performance
3 - Slight customer annoyance
6 - Some customer dissatisfaction
8 - High degree of customer dissatisfaction
10 - Product endangers the customer
Potential Cause(s) of the Failure:
Potential cause(s) of the failure are design weaknesses that can
result in the failure mode.

Examples include:
Insufficient Tolerance Insufficient
material thickness build-up material strength
Vibration Interference Overload
Contamination Insufficient bond Insufficient
coating/plating
Temperature Environment Electric power
(snow, salt water) interrupt

Occurrence:
Occurrence refers to the likelihood or frequency of the failure
mode occurring due to its related cause. Rank each effect:
1 - Failure is unlikely (0)
3 - Isolated cases (1 in 4000)
6 - Occasional failure (1 in 80)
8 - Frequent failures (1 in 20)
10 - Inevitable failures (1 in 2)

Design Controls:
Design controls are lab tests, field tests, mathematical studies, and
other inspection that can be implemented.