FMEA

RPN Rating Scale
Action to be taken
Lower
Upper
1
125
Move the X to Control Plan and record existing controls for X
126
300
Take immediate action on X to reduce RPN to less than 125
301
1000
Take X for Graphical and Statistical Analysis
Note: The above cut-off values are used as a thumbrule. Should you want to use
different cut-offs, please change the above values accordingly
Process / Product
Failure Modes and Effects Analysis
(FMEA)
Process or
Product
Name:
Responsible:
Prepared by:
Page ____ of ____
R
R
P
FMEA Date (Orig) ______________ (Rev) _____________
P
N
N
(
%
L
o
a
d
)
Action Results
(
L
Recommended
Action(s)
D
e
n
s
)
What are the actions for reducing the occurrence,

or improving detection, or for identifying the root
cause if it is unknown? ( Should have actions
only for RPN between 125 and 300 and Sev <7.
However, for obvious relationships or if it is
not advisable t
Responsibility
Who is
responsible for
the
recommended
action?
Completion
Date
What is the
completion date
for the
recommended
action?
Actions Taken
List the completed actions

that are included in the
recalculated RPN.
Include the implementation
date for any changes.
S
E
V
O
C
C
D
E
T
R
P
N
Are the detection limits improved?
What are the existing controls and

procedures (inspection and test) that
either prevent failure mode from
occurring or detect the failure should it
occur? Should include an SOP
number.
D
E
T
Recomkpute RPN after actions are

complete.
How can the failure occur?

Describe in terms of something
that can be corrected or controlled.
Be specific. Try identify the causes
that directly impacts the failure
mode, i.e., root causes.
Current
Process
Controls
What is the new severity?
Potential Cause(s)/
O
Mechanism(s) of Failure (Sub C
X's)
C
What is the new process capability?
What is the effect of each failure

mode on the outputs and/or
customer requirements?
The customer could be the next
operation, subsequent operations,
another division or the end user.
S
E
V
SEV x OCC x DET
In what ways might the process

The shortlisted X's from the potentially fail to meet the
C-E Matrix
process requirements and/or
design intent?
Potential Effects
of Failure (Y or Mini-Y)
SEV x OCC x DET
Potential Failure Mode

(How the X fails?)
How well can you detect cause or

FM?
Shortlisted inputs of
the process step
mentioned in Column
A
Characteristic of Input
(KPIV / X)
How often does the cause or failure

mode occur?
The highest
value process
steps from the
C&E matrix.
Input
How Severe is the effect to the

customer?
Process
Function
Major disruption to production line.

Loss of primary function, 100% scrap
Reduced primary function performance.

Product requires sorting, some scrapping
Minor disruption of production. Some Scrap.

Loss of secondary function performance
Minor disruption to produciton. 100% Rework.

Reduced secondary function performance.
Minor defect noticed by most customers

Product requires sorting and some reworked.
Fit& Finish/Squeak & Rattle item. Minor defect

noticed by some customers.
Defects may be reworked on-line.

Minor defect noticed by observant customers.
No effect
High
Moderate
May endanger machine or operator.

Hazardous with warning
Employe
Employ
Employe
Empl
Employe
re
Employe
Minor ch
Low
10
Extreme
Rating
None
Extreme
High
Moderate
Low
None
Severity of Effect
May endanger machine or operator.
Hazardous without warning
Minor
Extreme
High
Moderate
Low
None
Severity of Effect
Rating
Will definitely lead to attrition
10
Employee may complain to superior and express

thoughts about quitting
Employee may become irregular in attendance
Employee's quality of job reduces drastically and

also hinders others' work
Employee's efficiency of operation reduces
Employee might stop co-operating on matters not

related to his performance directly
Employee more vocal with colleagues on matters
leading to negative vibes.
Minor change in behaviour observed by superior
and colleagues
Minor change in behaviour, observed at few
occasions.
Will not lead to attrition
CUSTOMIZED VERSION
5
4
3
2
1
OCCURANCE RANKING TABLE F

Criteria: Possible Number of In
Sr.N Likelihood of Occurrence Rank
(Days)
1
2
3
4
5
6
7
8
9
10
occurs every hour
10
occurs every shift
occurs every Day
occurs every week
occurs every Bi week
occurs every month
occurs every 3 months
occurs every 6 months
occurs every year
occurs every 3 years
Note 1: Please change the sensitivity

of the scale by adjusting time unit at
various ratings e.g. converting day to
Criteria: Detection of Cause / Failure Mo
Detection
Criteria
Inspection
Types
A B
C
Almost
Absolute certainty of
Impossible non-detection
Very
Remote
Controls will probably

not detect
Remote
Controls have poor

chance of detection
Very Low
Controls have poor

chance of detection
Low
Controls may detect
Moderate
Controls may detect
Moderately Controls have a good

High
chance to detect.
High
Controls have a good

chance to detect.
Very High
Controls almost certain

to detect.
Very High
Controls certain to
detect
Inspection Types:
A. Error-proofed
B. Gauging
C. Manual Inspection
Criteria: Detection of Cause / Failure Mode

Suggested Range of Detection Methods
Cannot detect or is not checked
Control is achieved with indirect or random checks only.
Control is achieved with visual inspection only.
Control of achieved with double visual inspection only.
Control is achieved with charting methods, such as SPC (Statistical Process Control).
Control is based on variable gauging after parts have left the station, or Go/No Go
gauging performed on 100% of the parts after parts have left the station.
Error detection in subsequent operations, OR gauging performed on setup and firstpiece check (for set-up causes only).
Error detection in-station, or error detection in subsequent operations by multiple
layers of acceptance: supply, select, install, verify. Cannot accept discrepant part.
Error detection in-station (automatic gauging with automatic stop feature). Cannot
pass discrepant part.
Discrepant parts cannot be made because item has been error-proofed by process /
product design.
Ranking
10
9
8
7
6
5
4
3
2
1

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RPN Rating Scale

Page ____ of ____

What are the actions for reducing the occurrence,

List the completed actions

What are the existing controls and

Recomkpute RPN after actions are

How can the failure occur?

What is the new severity?

What is the new process capability?

What is the effect of each failure

SEV x OCC x DET

In what ways might the process

SEV x OCC x DET

Potential Failure Mode

How well can you detect cause or

How often does the cause or failure

How Severe is the effect to the

Major disruption to production line.

Reduced primary function performance.

Minor disruption of production. Some Scrap.

Minor disruption to produciton. 100% Rework.

Minor defect noticed by most customers

Fit& Finish/Squeak & Rattle item. Minor defect

Defects may be reworked on-line.

May endanger machine or operator.

Will definitely lead to attrition

Employee may complain to superior and express

Employee may become irregular in attendance

Employee's quality of job reduces drastically and

Employee's efficiency of operation reduces

Employee might stop co-operating on matters not

OCCURANCE RANKING TABLE F

occurs every hour

occurs every shift

occurs every Day

occurs every week

occurs every Bi week

occurs every month

occurs every 3 months

occurs every 6 months

occurs every year

occurs every 3 years

Note 1: Please change the sensitivity

Criteria: Detection of Cause / Failure Mo

Controls will probably

Controls have poor

Controls have poor

Controls may detect

Controls may detect

Moderately Controls have a good

Controls have a good

Controls almost certain

Criteria: Detection of Cause / Failure Mode

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