Severity, Occurrence, and Detection Criteria for Design FMEA

SEVERITY EVALUATION CRITERIA SUGGESTED DETECTION EVALUATION CRITERIA

EFFECT CRITERIA: Severity of Effect R NK. DETECTION CRITERIA RNK.
Design Control will not and/or cannot detect a potential cause/
Hazardous- Very high severity ranking when a potential failure mode affects safe Absolute
without vehicle operation and/or involves noncompliance with government 10 mechanism and subsequent failure mode; or there is no 10
Uncertainty Design Control.
warning regulation without warning
Very Remote chance the Design Control will detect a potential
Hazardous- Very high severity ranking when a potential failure mode affects safe Very Remote cause/mechanism and subsequent failure mode. 9
with vehicle operation and/or involves noncompliance with government 9
warning regulation with warning Remote chance the Design Control will detect a potential cause/
Remote mechanism and subsequent failure mode.
8
Very High Vehicle/item inoperable (loss of primary function). 8
Very Low chance the Design Control will detect a potential
Very Low cause/mechanism and subsequent failure mode.
7
Vehicle/item operable but at a reduced level of performance.
High
Customer very dissatisfied. 7
Low chance the Design Control will detect a potential cause/mech anism
Low and subsequent failure mode.
6
Vehicle/item operable but Comfort/Convenience item(s) inoperable.
Moderate
Customer dissatisfied. 6
Moderate chance the Design Control will detect a potential cause/
Vehicle/item operable but Comfort/Convenience item(s) operable at a Moderate mechanism and subsequent failure mode.
5
Low
reduced level of performance. Customer somewhat dissatisfied.
5
Moderately Moderately High chance the Design Control will detect a potential
Fit & Finish/Squeak & Rattle item does not conform. Defect noticed by
4 cause/mechanism and subsequent failure mode. 4
Very Low
most customers (greater than 75%). High
High chance the Design Control will detect a potential cause/
Fit & Finish/Squeak & Rattle item does not conform. Defect noticed by High 3
Minor
50% of customers. 3 mechanism and subsequent failure mode.

Very High chance the Design Control will detect a potential cause/
Fit & Finish/Squeak & Rattle item does not conform. Defect noticed by Very High 2
Very Minor
discriminating customers (less than 25%).
2 mechanism and subsequent failure mode.
Almost Design Controls will almost certainly detect a potential cause/
None No discernable effect. 1 1
Certain mechanism and subsequent failure mode.

SUGGESTED OCCURRENCE EVALUATION CRITERIA RPN THRESHOLD

Probability of
Failure
Very High: Persistent failures
High: Frequent failures
Moderate: Occasional failures
Low: Relatively few failures
Remote: Failure is unlikely
*Note: Zero (0) rankings for Severity, Occurrence or Detection are not allowed
Likely Failure Rates Over Design Life Ranking There is no threshold value for RPNs. In other words, there is
no value above which it is mandatory to take a
≥ 100 per thousand vehicles/items 10 Recommended Action or below which the team is automatically
50 per thousand vehicles/items 9 excused from an action.
20 per thousand vehicles/items 8
10 per thousand vehicles/items 7
5 per thousand vehicles/items 6
2 per thousand vehicles/items 5
1 per thousand vehicles/items 4
0.5 per thousand vehicles/items 3
0.1 per thousand vehicles/items 2
(313) 565 - 6266
≤ 0.01 per thousand vehicles/items 1 US (888) FOR - FMEA
CDN (877) 609-0999
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 FMEA - Quick Reference Guide
System Potential
Sub System FMEA Number:
X Component: Generic Decision
Failure Mode and Effects Analysis Page 1 of 1
Model Year/Vehicle (s): 98.5 Design Responsibility: QAI, Inc. (Design FMEA) Prepared by: Lee Dawson
Core Team: M. Moore, M. Weber, D. Wojcik, L. Dawson Key Date: Engineering Rel. 2/3/98 FMEA Date (orig.):
Item Potential Current
Potential Potential S Cl O D R. Responsibility Action Results
Cause(s)/ c Design e Recommended Actions S O D R.
Failure Effect(s) of e a c t P. & Target
v s Mechanism(s) u Controls e N. Action(s) Taken e c e P.
Mode Failure Completion Date
Function s Failure r Prevent Detect c v c t N.
Must provide an FMEA FMEA not • Product liability 10 YC Inadequate FMEA 5 •Design 2 100 Call an FMEA Design team leader FMEA performed 10 2 2 40
•Mistake verification,
which determines design adequately • Customer development Proofing facilitator to or project manager; under the supervision
planning
risk and addresses performed; high dissatisfaction • Cross functional reduce time required ASAP and leadership of
and testing
potential significant and risk remains • Reduced performance team not assembled •Training and improve quality an expert/certified
critical characteristic of system or • Facilitation not of the FMEA process FMEA facilitator
selection: component used
Measurable: • Potential risk of • FMEA expertise is
• Reduced RPN injury limited
• Number of significant Actions should: Brief action
and critical characteristics. • eliminate failure • Name of team
Detect result Recalculate RPN, after
• Number of design mode SEV=9/10 member to
Planned tests • eliminate causes description action has been
actions. carry issue.
Customer • Transfer to on YS Date action taken
or from DV Plan • Name of
focus/experience • reduce occurrence taken • occurrence
• evaluations • improve tests champion
• end user • builds • detection
Brainstorm causes “detection • Date action
• assembler • bucks Note: severity will
• Verb-noun • man reduction last desired
• maker • material Note: Must have option” likely stay the same
• measurable completion
Anti function • method written instructions. unless failure mode is
is desirable • regulatory
for functional • machine Prevent eliminated
• objective body •Reduces Occurrence
approach • environment
• subjective Determine Root
• full cause if YC
• partial
See Severity See Occurrence See Detection
• intermittent
Chart on Chart on Chart on
• excess function
opposite side opposite side opposite side

Actions are Required: Critical & Significant TM

(by Priority) Characteristics Action Guidelines FMEA EXPRESS

• Complete FMEAs more quickly
1.) When this exists (initiate 10 • Address high-risk potential
1.) Confirmed Critical Characteristic Top 20% of Failure
Process FMEA to verify) failure modes first
9 Modes by RPN • Use a cross-functional FMEA
8 team approach
S 2.) Confirmed Significant
2.) When this exists (initiate 7
Characteristic; Action
e
Process FMEA to verify) 6 Required R
v P
e 5 N
r
4
i ANNOYANCE
3.) For the top 20% Failure
t 3 ZONE US (888) FOR-FMEA
Modes / Causes (Pareto by 3.) RPN-Top
y US (313) 565 - 6266
RPN) 2 20% by pareto Failure Modes CDN (877) 609 – 0999
1
AUS 011 61 (03) 9585 - 6423
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Occurrence
© 1997 (REV: 04/2002)