Potential Failure Mode & Effects Analysis

(FMEA)
FMEA ASSISTANCE PROCESS MANUAL

Concept
(System) FMEA

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Potential Failure Mode & Effects Analysis
M&M FMEA ASSISTANCE PROCESS MANUAL FOR
CONCEPT FMEA (CFMEA)

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FMEA NUMBER
Enter the FMEA document number, which may be used for tracking
purpose.
Suggested Format : "System name - concept - vehicle model
affected - revision no."
e.g. Suspension-IFS-AFL-001
e.g. Brake-frt.discbrake-Grand LX-002

SYSTEM
Indicate the appropriate level of analysis and name / number of the
System or subsystem being analysed.
e.g. Suspension, Independent Front Suspension, 0101A2
e.g. Electrical, Lighting, 0101A1

DESIGN RESPONSIBILITY
Enter the name of the department and group. In case of Supplier's
FMEA, name of the Supplier / department at his end.
e.g. IDAM/Scorpio/Transmission
e.g. MICO/R&D/MDI3200

DESIGN RELEASE DATE

Enter the last date the Design should be released
Suggested Format : DD/MM/YY
e.g. 02/02/00

PREPARED BY
Enter the name of the department(s) and group(s) involved in concept
Design, which could also include external agencies like the Suppliers.
e.g. Veh. Tech. Group / Testing Group / Engine PU / MICO

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MODEL YEARS / VEHICLE(S)
Enter the intended model year(s) and vehicle line(s) that will utilise
and/or be affected by the Design being analysed (if known).
e.g. Grand LX/GrandAX/ARMADA
e.g. All models

FMEA DATE
Enter the date the original FMEA was compiled, and the latest revision
date.
Suggested Format : DD/MM/YY (at both the places, 'original' &
'revised')
e.g. 02/02/00

SUPPLIER(s) / PLANT(s) AFFECTED

List the names of the Assembly / Manufacturing plants, including those
of the Suppliers.
e.g. M&M-Igp/M&M-Z'bad/Lucas

CORE TEAM
List the names of the responsible individuals and departments that
have participated in the FMEA and also have the authority to identify
and / or perform tasks.
Suggestion : It is recommended that all Team members’ names,
departments, telephone numbers, addresses, etc., be included on
a distribution list.
e.g. SLK, SKD, SRT, AGK, NMP, APV, MMN (Susp. Team / 022-
8874601-2835 / IDAM)

ITEM / FUNCTION
Concept function is the original intent or purpose(s) of the concept
proposal. Concept functions are derived from Customer Wants.
Concept functions can also include Safety requirements, Government
Regulations and Organisational Constraints / Considerations. Review
QFD studies and information from any other Customer surveys.

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 List all the Concept functions, and any other constraints on the
proposed concept. Describe functions in specific terms. It may be
helpful to use Verb-Noun combinations to describe the functions.
However, if Verb-Noun terms are used, avoid the use of general verbs
like “provide, facilitate, allow” to describe a functional requirement.
Constraints may include, for example, weight, size, location,
accessibility, etc. Use the Item / Function List to facilitate this Process.
Refer Appendix – B for a brief on Item / Function Worksheet
Construct a Concept Functional Block Diagram. The diagram should
show the concept elements as functional blocks into which the
proposal may be decomposed. It is important to identify the major
elements, understand how they interact, and the proposal may interact
with outside systems.
Refer to Appendix – C for a brief on Constructing the Functional Block
Diagram.
Identify the Engineering requirements associated with each function,
where known. Requirements may include, for example, operational
parameters such as magnitude, rate, colour, etc.

POTENTIAL FAILURE MODE

Potential Failure is a loss of loss of the function.
For each function, list the corresponding loss of the function. Describe
the failure mode in terms of loss of the function (partial or intermittent),
or as the negative function.
Brainstorm potential failure modes by asking “In what way can this
concept fail to perform its intended function?"
List the potential failure mode for each function. Examples could be :
Cannot generate light
Cannot clean windshield
Cannot stop vehicle
Cannot power ignition
Cannot steer vehicle
Cannot control speed
Cannot dispense fuel
Operates at wrong time
Operates prematurely

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 Operates intermittently

POTENTIAL EFFECT(S) OF FAILURE

A potential effect of failure is the consequence of a failure mode in
terms of its impact on other systems, the vehicle, the customer and the
government regulations. For a concept, the failure effect is generally
the manner in which the customer observes, or experiences, the failure
mode.
Review field Service data and other pertinent documents to identify
known effect(s) of failure mode of similar systems.
Determine the consequence(s) of the loss function. Consider the
consequences on the proposed concept, other systems, the vehicle,
and the customer.
For each failure mode, list its consequences on other systems, the
vehicle, and the customer. If safe vehicle operation, or compliance
with government regulations is affected, note it in this column. Example
could be,
Other systems : None
Vehicle : None
Customer : Vision may be impaired
Government : May not comply with CMVR-XYZ009

SEVERITY
Severity is an assessment of the seriousness of the effect (listed in the
previous column) of potential failure mode to the next subsystem, or
customer if it occurs. Severity applies to the effect only.
Consider the effect of the failure mode on other systems, the vehicle,
the customer, and on government regulations. For each potential effect
of failure, assign a Rating from the Severity Rating Table.
Refer to the Severity Rating Table in Appendix – A1.
Rank failure modes on the basis of the Severity of their effects.
Select the highest Rating (worst effect) for the failure mode.

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CLASSIFICATION
This column is not currently used for Concept FMEA. In the early
stages of development, hardware has not yet been defined. Until
hardware is defined, potential Special Characteristics cannot be
identified.
After hardware is identified, a Design FMEA can be used to identify
potential Special Characteristics, i.e., Critical & Significant
Characteristics.
Refer to the MQS guidelines on Special Characteristics.

POTENTIAL CAUSE(S) / MECHANISM(S) OF FAILURE

The cause of the a failure mode is the potential concept deficiency by
Design intent that results in the failure mode. Identification of causes
should begin with those failure modes with the highest Severity Rating.
A failure mode can be caused by one or more element failure modes,
or by :
 Interface or interaction between elements
 Interaction of an element with other systems
 Interaction with the environment
 Interaction with the customer (including ergonomics, operating
instructions)
It is assumed there is one concept proposal for each vehicle, and that
the Design life of the proposal is equal to the vehicle life. If the
cumulative number of failures of the element over the Design life
cannot be estimated, then the cumulative number of failures over the
Design life of the concept based upon similar, or surrogate systems is
taken as the basis. If neither cumulative number can be estimated,
then judge the likelihood that the potential cause / failure mechanism
and its resultant failure mode will occur over the Design life of the
proposal.
The FMEA Team should consense on an Occurrence Rating for each
cause using the Occurrence Rating Table for Concept FMEA.
For each potential cause listed enter a Rating from the Occurrence
Rating Table.
Refer to the Occurrence Rating Table in Appendix – A2.

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 If the failure rate is between ranges, enter the higher Rating. If the
Occurrence Rating cannot be estimated, or the Team cannot reach a
consensus, then enter a Rating of 10.
Example : Assume there will be two elements within the concept and
one arrangement installed in each vehicle. Assume the element
Design life is 50,000 kilometers and the proposal Design life is 200,000
kilometers. Assume the Team estimates that there will be one element
failure for every 1000 element produced. In this instance :
Failure rate = (1 failure/1000 elements) X (2 elements/System) X
(200,000km/50,000km) = 8 in 1000 or 1 in 125
In addition, according to the Occurrence Rating Table, the Rating is
between 5 and 6. Therefore, the next higher Rating is entered, i.e.,
Occurrence Rating will be 6.

CURRENT DESIGN CONTROLS

Design Control is an Engineering analysis tool (e.g., load calculations,
Finite Element Analysis), test, Design review, or other advanced
inspection or Control method. These methods are used to detect the
first level causes (element failure modes) of concept failure modes.
The object of a Control method is to detect a potential deficiency as
early as possible in the concept validation phase. A concept deficiency
is considered a fault or weakness in an element that can cause a
System failure mode within the Design proposal.
To prevent potential failure modes, it is important to be able to expose,
or detect, potential deficiencies early in the Design Process. Early
Detection leads to timely remedial actions and changes in the SDSs
(System Design Specifications).
Review historical information (proving ground tests, fleet test,
laboratory tests, environmental tests, prototype tests, mathematical
modeling studies, etc.). Identify similar types of element failure modes
experienced with similar surrogate systems. Assess the ability to
detect historical element failure modes. List current Detection
methods used with the same or similar systems to detect the potential
failure modes.
Brainstorm new methods, tests, or techniques that can be employed to
detect the potential failure modes by asking :
 In what way can this element failure mode be recognised?
 How could I discover that this element failure mode has
occurred?

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  How will this concept proposal be validated?
List a description of the Control method(s) that will be used to detect
the first level causes (element failure modes) of the failure mode.
If a method, test or technique cannot be identified, then enter “None
identified at this time.” Examples of Design Controls could include
Computer Simulation(s), Mathematical Model(s), Laboratory
test(s) on surrogate component(s), etc.

DETECTION
Detection is a Rating corresponding to the likelihood that the Detection
method(s) will detect the first level causes of potential failure mode.
Estimate the capability of each Detection method to detect the first
level cause (element failure mode) of the potential failure mode.
Consider the capability of each method to detect the element failure
mode or first level causes. Assume the element failure mode has
occurred. Also, consider how early in the proposal phase of the
program the method will be used.
Consider all the Detection methods. Determine a Rating for each
Detection method. The FMEA Team should consense on a Detection
Rating for each method using the Detection Rating Table for Concept
FMEA.
Refer to the Detection Rating Table in Appendix – A3.
When multiple Detection methods are listed, select the lowest
(best) Detection Rating.
If methods, tests, or techniques cannot be identified, or the Team
cannot reach a consensus, then use the highest Rating in the
Detection Rating table.

RISK PRIORITY NUMBER (RPN)

The Risk Priority Number is the Product of the Severity, Occurrence
and Detection Ratings.
RPN = (S) x (O) x (D)
Rank the resultant RPN numbers from high to low for prioritising
purpose.
Remember that RPN numbers in themselves have no value or
meaning. RPNs are only one method used only to rank the concept
deficiencies for recommended actions.

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RECOMMENDED ACTION(S)
The FMEA Team should prioritise actions based on those failure
modes :
 With effects that have the highest Severity Ratings
 With causes that have the highest Occurrence Ratings
 With the highest RPNs
Design requirements may be translated into System or hardware
Engineering specifications and incorporated into a System Design
Specification (SDS) for future programmes.
If no actions are recommended for a specific cause, it is
permissible to enter “No action at this time.” (this prevents
someone interpreting a blank space as an oversight or an
incomplete resolution.)
Typical actions may include the following :
 Modify the proposal to eliminate its failure mode or reduce its
rate of Occurrence.
 Add a redundant System that allows System operation to
continue at the same functional level if the System fails.
 Provide other modes of operation that allow proposed operation
to continue at the same, or at a degraded functional level.
 Add built-in Detection devices to alert the customer to take
action that will prevent a failure mode, or reduce its rate
Occurrence.
 Specify a certain type of material.

RESPONSIBILITY AND TARGET COMPLETION DATE

The Organizational department or System activity, the System
Engineer responsible for the Recommended Action, and the target
completion date of the action.
e.g. R&D Test Facility / Mr. DMM / 02.02.2000
e.g. CAD Centre / Mr. APC / 02.02.2000

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ACTIONS TAKEN
FOLLOWUP : The need for actions with qualified benefits, and
following up all recommended actions need not be over-emphasised.
A thorough Concept FMEA will be of limited value without positive and
effective actions to prevent defects.
It is the responsibility of the Engineer, who responsible for the Concept
FMEA, to implement a follow-up program to ensure all recommended
actions have been implemented or adequately addressed. At a
minimum, the Design Engineer must verify all applicable System
Design Specifications (SDSs) are updated and correct.
The System Design Engineer is responsible for updating the Concept
FMEA.
The FMEA is a living document and should reflect the latest proposal
level, and the latest relevant actions.
After an action has been taken, enter a brief description of the action,
and its effective or actual completion date.

RESULTING RPN
After actions are taken, the Ratings for Severity, Occurrence and
Detection are revised by the FMEA Team. The revised RPNs are
calculated and ranked.
The revised RPNs should be reviewed by the System Design Engineer
to determine if further Design actions are necessary.
After actions are taken, and reevaluated, enter the Ratings for Severity,
Occurrence, and Detection. Calculate and enter the resultant RPN.
If no action are taken, leave columns for Severity, Occurrence &
Detection blank.

IMPORTANT !!!
After you have completed the CFMEA, it is advisable that a review of
Quality of the FMEA prepared be done. This is essential to ensure that
a Quality of Event (QoE) has taken place.
Refer to Appendix – D for Check-sheet for Evaluation of a Concept
FMEA.

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Appendix – A1

Concept FMEA
Severity Rating Table
Effect Criteria Rating
Hazardous Hazardous effect. Safety related – sudden 10
Effect failure. Non-compliance with Government
regulations.
Serious Potential hazardous effect. Able to stop 9
Effect vehicle without mishap – gradual failure.
Compliance with Government regulations in
jeopardy
Extreme Customer very dissatisfied. Vehicle 8
Effect inoperable, but safe. System inoperable.
Major Customer dissatisfied. Vehicle performance 7
Effect severely affected but driveable and safe.
System function impaired.
Significant Customer experiences discomfort. Vehicle 6
Effect. performance degraded, but operable and
safe. Partial loss of system function, but
operable.
Moderate Customer experiences some dissatisfaction. 5
Effect Moderate effect on vehicle or system
performance.
Minor Customer experiences minor annoyance. 4
Effect Minor effect on vehicle or system
performance.
Slight Customer slightly annoyed. Slight effect on 3
Effect vehicle or system performance.
Very Customer not annoyed. Very slight effect on 2
Slight vehicle or system performance.
Effect
No Effect No effect. 1

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Appendix – A2

Concept FMEA
Occurrence Rating Table
Occurrence Criteria Rating
Almost Failure almost certain to occur. History of 10
Certain many failures with previous or similar
designs.
 1 in 2
Very High Very high number of failures likely. 9
1 in 3
High High number of failures likely. 8
1 in 8
Moderately Moderately high number of failures likely. 7
High 1 in 20
Medium Medium number of failures likely. 6
1 in 80
Low Occasional number of failures likely. 5
1 in 400
Slight Few number of failures likely. 4
1 in 2,000
Very Slight Very few number of failures likely. 3
1 in 15,000
Remote Rare number of failures likely. 2
1 in 15,000
Almost Failures unlikely. History of similar designs 1
Never show no failures.
 1 in 1,500,000

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Appendix – A3

Concept FMEA
Detection Rating Table
Effect Criteria Rating
Almost No known method available. 10
Impossible
Remote Only unproven or unreliable methods 9
available.
Very Slight Proving ground durability tests on vehicles 8
with system elements installed.
Slight Tests on vehicles with prototype system 7
elements installed.
Low Tests on similar system elements. 6
Medium Tests on pre-production system elements. 5
Moderately Tests on early prototype system elements. 4
High
High Simulation / modeling techniques available 3
in early design stage.
Very High Proven computer analysis programs 2
available in early design stage.
Almost Proven detection methods available in early 1
Certain concept stage.

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Appendix – B

ITEM FUNCTION WORKSHEET

The Item Function worksheet is used to determine the scope and prioritise,
organise the work efforts involved in conducting a Design FMEA. Based
on the rankings the Team can prioritise the focus.

ITEM FUNCTION WORKSHEET

Description :
Function :
What is the item supposed to do?
What is the item not supposed to do?
List all the functions and separate them from the specifications.
Determine the heirarchy of the function and assign an initial ranking.
Function Description Specifications Ranking
Verb-Noun How Much? When?

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Appendix – C

FUNCTIONAL BLOCK DIAGRAM

It is necessary that the scope of analysis of the subject of concept / system
FMEA is identified, i.e. those vehicle / system elements that will be
included & also excluded from the analysis. A Functional Block Diagram
helps to define the scope of analysis. The scope, on many occasions may
be self-determining by the nature of the product, nevertheless, it is
essential that the team share a common understanding of the scope from
the outset.
By clearly defining the scope, the team will maximise the opportunities for
identifying potential system failure modes. The underlying principle for
effectiveness could be to analyse vehicle systems and identify best
opportunities for failure prevention (Systems Engineering approach),
rather than limiting the scope to engineering responsibilities. In such
cases, it will be required to include additional team members who are
responsible for certain aspects outside the boundary of the system (but
have an influence on the system performance), e.g. other Systems
Engineers, Suppliers, etc.
A Functional Block Diagram describes the analysis boundary that
encapsulates all such items that form the part of the system and also
those that interface with the subject system. Using a simple block diagram,
individual system elements are shown in relationships / interactions with
each other, within and outside the system.

Guidelines / Rules for constructing a Functional Block Diagram

There are no hard rules for constructing a Functional Block Diagram,
hoeever, some basic guidelines are as listed below,
 Start at the highest level of interest. If you are interested in a System,
start there. If you are interested in a Assembly, start there.
 Determine the next lower level elements (blocks) that make up the
System, Sub-system, Assembly, etc. Go to succedding lower levels
according to the details available.
 Make sure every function is included in within one or more blocks.
 Show functions in the sequence in which they are performed.
 Identify inputs to the System (including inputs from the Customer) and
outputs from the Systrem.
 Determine the interrelationships / interfaces among the elements
(blocks) of the System
 Illustrate the flow of Information, Signals, Fluid, Energy, Force, etc..
 Draw lines showing inputs, outputs, relationships and flow.
 Label all the blocks and lines

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Appendix – C

FUNCTIONAL BLOCK DIAGRAM (contd….)

An example of a Head Light System may be as

shown below,

Electrical Power Body

USER Input Light Headlamp LIGHT

Mechanism Source Assy.

Aiming
Mechanism

Legend :
: System Boundary :

: Desired Output

: Mechanical Interface

: Electrical Interface (wire / connector)

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Appendix – D

Proposed Checklist for Concept FMEA

Use the checklist to verify various facets of a Quality FMEA. All the
answers should be “Y”, thus ensuring a Quality of Event (QoE)
Headings Y/N Checks
Preliminaries Is a block diagram made?
Was a CFT used for making the FMEA?
Is there an evidence that the background /
historical information (similar FMEAs, Lessons
Learned, Benchmarking Data, Other relevant
data, etc.) used?
Header Are all the applicable entries in the header
Information complete?
Purpose / Is the Concept function / Purpose clear &
Function complete?
Are the functions described in verb-noun format?
Are the functions measurable?
Failure Modes Are failure modes identified as a loss of function
(Total, Partial, Intermittent)?
Failure Effects Are the effects on safe vehicle operation and
government regulations considered?
Are the effects on other systems, the vehicle and
the customer considered?
Failure Causes / Are all causes for each failure mode identified?
Mechanisms
Are all causes in terms of element failure modes?
Design Controls Can methods listed detect the first level causes
(element failure modes) of the failure modes?
Severity Rating Are ratings based upon the most serious effect of
the failure mode?
Occurrence Are ratings based on cumulative number of
Rating failures that could occur for each cause over the
proposed life of the system?

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Appendix – D
Proposed Checklist for Concept FMEA (contd….)

Headings Y/N Checks

Detection Are ratings based on the likelihood of
Rating detecting the first level causes (element
failure modes) of the failure mode?
Risk Priority Are the RPNs ranked from high to low
Number (RPN)
Recommended Are the remedial actions considered for the
Actions highest ranked failure modes?
Are responsibility & timing for the listed
actions listed?
Are the actions directed towards elimination
or reduction of the Occurrence of the causes
of the failure modes?
Is the resultant RPN less than the
corresponding earlier RPN?
Follow-up Was the FMEA updated after the
recommended actions were taken and
implemented?

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