Process FMEA

FMEA Instructions
1) Identify and name the process, product or service. Identify who has responsibility, and identify the team.
2) List the item functions in column A.
3) Identify possible failure modes in column B.
4) Describe potential effect(s) of failure modes in column C.
5) Use the provided table (in the Rating Factors Tab) to identify severity in column D.
6) Identify potential causes of failure in column E. Describe these in terms of something that can be corrected or can be controlled.
7) Rate the liklihood of the identified failure casue occurring in column F. Use the provided table in the Rating Factors Tab.
8) Describe the current process controls to prevent the failure mode in column G.
9) Use the provided table (in the Ratings Factors Tab) to determine the liklihood that that failure cause will be detected.
10) The Risk Priority Number will be calculated automatically.
11) Use the RPN to identify further actions in columns J, K, and L. Once action is taken, recalculate RPN.

Prepared by:
Item Name: FMEA Team:
FMEA Date (Orig): Revision #:

Potential Effect on S O D R S O D
Process Step or Variable or Future
Potential Failure Mode Customer Because of E Potential Causes C Current Process Controls E P Actions Recommended Resp.& Target Date Actions Taken E C E
Key Input RPN
Defect V C T N V C T

cause likely to Occur?

How Severe is effect

rank order concerns

Detection of cause?

Future Occurance
What is the impact on the What are the actions for

Risk Priority # to

Future Detection
to the customer?

How probable is
How frequent is

In what ways can the Process
Step, Variable, or Key Input (customer requirements) or
What is the process step?
go wrong? (chance of not
meeting requirements)
Future Severity
What are the existing What were the actions
Key Output Variables reducing the Occurrence of
What causes the Key Input controls that either prevent Who's Responsible for the implemented? Include
the cause, or improving
to go wrong? (How could the failure mode from recommended action? What completion month/year.
internal requirements if Detection? Should
the failure mode occur?) occurring or detect it should date? (Then recalculate resulting
failure mode is not have actions on high RPN's
it occur? RPN.)
prevented or corrected ? or Severity of 9 or 10.

Unauthorized cash Block ATM cards after three

Unauthorized access withdrawal 8 Lost or stolen ATM card 3 failed authentication 3 72
Very dissatisified customer attempts

ATM PIN Authentication

Install load balancer to

Authentication failure Annoyed customer 3 Network failure 5 distribute work load across 5 75
network links

Cash not disburshed Dissatisfied customer 7 ATM out of cash 7 4 196

Account debited but no cash Transaction failure

Dispense Cash Very dissatisfied customer 8 3 4 96
disbursed Network issue

Bills stuck to each other

Extra cash dispensed Bank loses money 8 2 3 48
Bills stacked incorrectly

All Rights Reserved, Juran Institute, Inc. Process Design and Process FMEA
 Process FMEA

FMEA Instructions
1) Identify and name the process, product or service. Identify who has responsibility, and identify the team.
2) List the item functions in column A.
3) Identify possible failure modes in column B.
4) Describe potential effect(s) of failure modes in column C.
5) Use the provided table (in the Rating Factors Tab) to identify severity in column D.
6) Identify potential causes of failure in column E. Describe these in terms of something that can be corrected or can be controlled.
7) Rate the liklihood of the identified failure casue occurring in column F. Use the provided table in the Rating Factors Tab.
8) Describe the current process controls to prevent the failure mode in column G.
9) Use the provided table (in the Ratings Factors Tab) to determine the liklihood that that failure cause will be detected.
10) The Risk Priority Number will be calculated automatically.
11) Use the RPN to identify further actions in columns J, K, and L. Once action is taken, recalculate RPN.

Prepared by:
Item Name: FMEA Team:
FMEA Date (Orig): Revision #:

Potential Effect on S O D R S O D
Process Step or Variable or Future
Potential Failure Mode Customer Because of E Potential Causes C Current Process Controls E P Actions Recommended Resp.& Target Date Actions Taken E C E
Key Input RPN
Defect V C T N V C T

cause likely to Occur?

How Severe is effect

rank order concerns

Detection of cause?

Future Occurance
What are the actions for

Risk Priority # to
to the customer?

Future Detection
How probable is
How frequent is

Future Severity
What are the existing What were the actions
In what ways can the Process What is the impact on the reducing the Occurrence of
What causes the Key Input controls that either prevent Who's Responsible for the implemented? Include
Step, Variable, or Key Input Key Output Variables the cause, or improving
What is the process step? to go wrong? (How could the failure mode from recommended action? What completion month/year.
go wrong? (chance of not (customer requirements) or Detection? Should
the failure mode occur?) occurring or detect it should date? (Then recalculate resulting
meeting requirements) internal requirements? have actions on high RPN's
it occur? RPN.)
or Severity of 9 or 10.

All Rights Reserved, Juran Institute, Inc. Process Design and Process FMEA
 Process FMEA

FMEA Instructions
1) Identify and name the process, product or service. Identify who has responsibility, and identify the team.
2) List the item functions in column A.
3) Identify possible failure modes in column B.
4) Describe potential effect(s) of failure modes in column C.
5) Use the provided table (in the Rating Factors Tab) to identify severity in column D.
6) Identify potential causes of failure in column E. Describe these in terms of something that can be corrected or can be controlled.
7) Rate the liklihood of the identified failure casue occurring in column F. Use the provided table in the Rating Factors Tab.
8) Describe the current process controls to prevent the failure mode in column G.
9) Use the provided table (in the Ratings Factors Tab) to determine the liklihood that that failure cause will be detected.
10) The Risk Priority Number will be calculated automatically.
11) Use the RPN to identify further actions in columns J, K, and L. Once action is taken, recalculate RPN.

Prepared by:
Item Name: FMEA Team:
FMEA Date (Orig): Revision #:

S O D R S O D
Process Step or Variable Potential Effect on Customer Future
Potential Failure Mode E Potential Causes C Current Process Controls E P Actions Recommended Resp.& Target Date Actions Taken E C E
or Key Input Because of Defect RPN
V C T N V C T

What are the actions for

Detection of cause?

Future Occurance
Risk Priority # to

Future Detection
How probable is
How frequent is

Future Severity
What are the existing reducing the Occurrence What were the actions

cause likely to
How Severe is
effect to the
In what ways can the Process Step, What is the impact on the Key

rank order
customer?

concerns
controls that either of the cause, or improving Who's Responsible for the implemented? Include

Variable, or Key Input go wrong?
What is the process step?
(chance of not meeting
requirements)
Occur?
Output Variables (customer What causes the Key Input to go wrong?
prevent the failure mode Detection? Should recommended action? completion month/year.
requirements) or internal (How could the failure mode occur?)
from occurring or detect have actions on high What date? (Then recalculate
requirements?
it should it occur? RPN's or Severity of 9 or resulting RPN.)
10.

Agent may not understand customer

requirement due to language barrier. 48

An FCR may not be provided,  Call listening from

Flight Selection
Agent system proficiency  due to different profile & need of 4 3 customer perspective and 4
the customer feedback
Agent may not come up with alternative but
work on customer assign way, Due to
product knowledge or updates.

• Agent fail to use all the tools and • Customer may not get FCR and
resources to validate or obtain the will have to call back, increasing 4 • Product Knowledge • Periodic product test
information before delivering  a dissatisfaction with United

Utilizing tools and resources • Agent took a longer time to find out • Customer may end up getting 6 4 96
correct information due to wrong information , which will • Updated information issue • Daily Huddle
inappropriate system proficiency  impact travel experience 

• Lack of system proficiency will

• Agent failed to check all the options
have impact on time taken on
available before coming to an • System proficiency  • Coaching and feedback
delivery, which has a financial
conclusion 
loss for the company 
• Self-made information

All Rights Reserved, Juran Institute, Inc. Process Design and Process FMEA
 Design FMEA

FMEA Instructions
1) Identify and name the process, product or service. Identify who has responsibility, and identify the team.
2) List the item functions in column A.
3) Identify possible failure modes in column B.
4) Describe potential effect(s) of failure modes in column C.
5) Use the provided table (in the Rating Factors Tab) to identify severity in column D.
6) Identify potential causes of failure in column E. Describe these in terms of something that can be corrected or can be controlled.
7) Rate the liklihood of the identified failure casue occurring in column F. Use the provided table in the Rating Factors Tab.
8) Describe the current process controls to prevent the failure mode in column G.
9) Use the provided table (in the Ratings Factors Tab) to determine the liklihood that that failure cause will be detected.
10) The Risk Priority Number will be calculated automatically.
11) Use the RPN to identify further actions in columns J, K, and L. Once action is taken, recalculate RPN.

Prepared by:
Item Name: FMEA Team:
FMEA Date (Orig): Revision #:

Potential Effect on S O D R S O D
Future
Item Function Potential Failure Mode Customer Because of E Potential Causes C Current Process Controls E P Actions Recommended Resp.& Target Date Actions Taken E C E
RPN
Defect V C T N V C T
F
u

cause likely to Occur?

How Severe is effect

rank order concerns

Detection of cause?

Future Occurance
What are the Existing What are the actions for

Risk Priority # to
to the customer?

Future Detection
t

How probable is
How frequent is

In what ways can the
What is the component, Component, Subsystem or
function, or feature? System potentially fail to
meet the Design Intent ?
Future Severity
What were the actions
What is the impact on the Controls & Procedures (Fail- reducing the Occurrence of u
List every conceivable failure Who's Responsible for the implemented? Include
Key Output Variables Safe, Tests, the cause, or improving r
and/or failure mechanism recommended action? What completion month/year.
(customer requirements) or Mathemat.Calcs)that prevent Detection? Should have e
for each failure mode date? (Then recalculate resulting
internal requirements? either the cause or the actions on high RPN's or
RPN.) R
failure mode EASY FIXES
P
N

All Rights Reserved, Juran Institute, Inc. Process Design and Process FMEA
 Design and Process FMEA Rating Factors

RATING DEGREE OF SEVERITY PROBABILITY OF OCCURRENCE ABILITY TO DETECT

FREQUENCY Detection
( 1 in … ) Certainty
Customer will not notice the adverse Likelihood of Sure that the potential failure will be
1 effect or it is insignificant occurrence is remote 1,000,000 found or prevented before reaching the 100%
next customer
Customer will probably experience Low failure rate with Almost certain that the potential failure
2 slight annoyance supporting 20,000 will be found or prevented before 99%
documentation reaching the next customer
Customer will experience annoyance Low failure rate Low likelihood that the potential failure
3 due to the slight degradation of without supporting 5,000 will reach the next customer undetected 95
performance documentation
Customer dissatisfaction due to reduced Occasional failures Controls may detect or prevent the
4 performance 2,000 potential failure from reaching the next 90
customer
Customer is made uncomfortable or Relatively moderate Moderate likelihood that the potential
their productivity is reduced by the failure rate with failure will reach the next customer
5 500 85
continued degradation of the effect supporting
documentation
Warranty repair or significant Moderate failure rate Controls are unlikely to detect or
manufacturing or assembly complaint without supporting prevent the potential failure from
6 100 80
documentation reaching the next customer

High degree of customer dissatisfaction Relatively high failure Poor likelihood that the potential failure
due to component failure without rate with supporting will be detected or prevented before
7 complete loss of function. Productivity documentation 50 reaching the next customer 70
impacted by high scrap or rework levels.

Very high degree of dissatisfaction due High failure rate Very poor likelihood that the potential
to the loss of function without a without supporting failure will be detected or prevented
8 20 60
negative impact on safety or documentation before reaching the next customer
governmental regulations
Customer endangered due to the Failure is almost Current controls probably will not even
adverse effect on safe system certain based on detect the potential failure
9 performance with warning before failure warranty data or 10 50
or violation of governmental regulations significant Design
Verification* testing
Customer endangered due to the Assured of failure Absolute certainty that the current
adverse effect on safe system based on warranty controls will not detect the potential
10 performance without warning before data or significant 2 failure < 50
failure or violation of governmental Design Verification*
regulations testing

*Design Verification Testing (DVT): Test conducted when designing new products/services to verify that the optimal process design performs at the
level specified by customer requirements (CTQs). DVT is a methodical approach used to identify and resolve problems before finalizing the process
for new products/services.

All Rights Reserved, Juran Institute, Inc. Rating Factors Design and Process FMEA
RPN VALUE RISK CATEOGARY
1-50 Very Low
51-100 Low
101-150 Medium
151-200 High
201-250(>250) Very High
RISK CONTROL
Accept
accept
Avoid
Mitigate
Mitigate