Failure M

Process Name:
Person In
Charges:

S
Key Process Potential Failure Potential Failure Potential
E
Step or Input Mode Effects Causes
V

How Severe is the

effect to the
customer?
What is the In what ways can What is the impact What causes the
Process Step or the Process Step or on the Key Output Key Input to go
Input? Input fail? Variables once it wrong?
fails (customer or
internal
requirements)?
Failure Modes Effects Analysis
Prepared by:

Created Date :

O D R
Actions
C Current Controls E P
Recommended
C T N
How often does
cause or FM
occur?

How well can you

detect the Cause
or the Failure
Mode?
What are the existing What are the actions
controls and for reducing the
procedures that occurrence of the
prevent either the cause, or improving
Cause or the Failure detection?
Mode?

0
0
 Rev.

S O D R
Actions
Resp. E C E P
Taken
V C T N

Who is Responsible for Note the

the recommended actions
action? taken.
Include
dates of
completion.

0
0
 Severity of Effect Rating
Extreme May endanger machine or operator.
10
Hazardous without warning
May endanger machine or operator.
9
Hazardous with warning
Major disruption to production line.
8
Loss of primary function, 100% scrap
High

Reduced primary function performance.

7
Product requires sorting, some scrapping
Minor disruption of production. Some Scrap.
6
Loss of secondary function performance
Moderate

Minor disruption to produciton. 100% Rework. Reduced

5
secondary function performance.
Minor defect noticed by most customers
4
Product requires sorting and some reworked.
Fit& Finish/Squeak & Rattle item. Minor defect noticed by some
3
customers.
Low

Defects may be reworked on-line.

2
Minor defect noticed by observant customers.
None

No effect 1
 Failure Capability
Likelihood of Occurrence Rate (Cpk) Rating
1 in 2 < .33 10
High
Very

Failure is almost inevitable

1 in 3 > .33 9
Process is not in statistical control. 1 in 8 > .51 8
Low ModerateHigh

Similar processes have experienced problems. 1 in 20 > .67 7

Process is in statistical control but with isolated failures. 1 in 80 > .83 6
Previous processes have experienced occasional 1 in 400 > 1.00 5
failures or out-of-control conditions. 1 in 2000 > 1.17 4
Process is in statistical control. 1 in 15k > 1.33 3

Process is in statistical control. Only isolated

Re- Very
mote Low

1 in 150k > 1.50 2

failures associated with almost identical processes.
Failure is unlikely. No known failures associated
1 in 1.5M > 1.67 1
with almost identical processes.
 Likelihood that control will detect failure DPPM Probability
HighModerate Low Very Low

No known control(s) available to detect failure mode. 100,000 1 in 10

50,000 1 in 20
Controls have a remote chance of detecting the failure.
20,000 1 in 50
10,000 1 in 100
Controls may detect the existence of a failure 5,000 1 in 200
2,000 1 in 500
1,000 1 in 1,000
Controls have a good chance of detecting the existance of a failure
500 1 in 2,000
The process automatically detects failure. 200 1 in 5,000
High
Very

Controls will almost certainly detect the existence of a failure. 100 1 in 10,000
Rating

10
DPPM Defect Part Per Milion
9
8
7
6
5
4
3
2
1