8/14/2019 Six Sigma Consultants, 1996

1/24

Six Sigma Consultants, 1996

PFMEA Information Sheet

Failure Mo

FMEA Number:

Process Name:

Process Responsibility:

Prepared By:

Affected Product(s):

PFMEA Key Date:

FMEA Origination Date:

FMEA Revision Date:

Team Members:

TM

8/14/2019 Six Sigma Consultants, 1996

2/24

8/14/2019 Six Sigma Consultants, 1996

3/24

Six Sigma Consultants

FMEA

# C l a s s

1 0

2 0

3 0

4 0

5 0

6 0

7 0

8 0

9 0

10 011 0

12 0

13 0

14 0

15 0

16 0

17 0

ProcessFunction

(Step)

PotentialFailureModes

(processdefects)

PotentialFailureEffects

(KPOVs)

SEV

PotentialCauses of

Failure(KPIVs)

OCC

CurrentProcessControls

DET

RPN

Recommend Actions

ResponsPerso

Target D

8/14/2019 Six Sigma Consultants, 1996

4/24

Six Sigma Consultants

FMEA

# C l a s sProcess

Function(Step)

PotentialFailureModes

(processdefects)

PotentialFailureEffects

(KPOVs)

SEV

PotentialCauses of

Failure(KPIVs)

OCC

CurrentProcessControls

DET

RPN

Recommend Actions

ResponsPerso

Target D

18 0

19 0

20 0

21 0

22 0

23 0

24 0

25 0

26 0

27 0

28 0

29 0

30 0

31 0

32 0

33 0

34 0

35 0

36 0

8/14/2019 Six Sigma Consultants, 1996

5/24

8/14/2019 Six Sigma Consultants, 1996

6/24

Six Sigma Consultants

FMEA

0

0

0

0

0

0

0

0

0

00 `

0

0

0

0

0

0

TakenActions

SEV

OCC

DET

RPN

8/14/2019 Six Sigma Consultants, 1996

7/24

Six Sigma Consultants

FMEA

TakenActions

SEV

OCC

DET

RPN

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

8/14/2019 Six Sigma Consultants, 1996

8/24

Six Sigma Consultants

FMEA

TakenActions

SEV

OCC

DET

RPN

0

0

0

0

0

0

0

0

0

0

0

0

0

0

8/14/2019 Six Sigma Consultants, 1996

9/24

Severity

Page 9

Effect

Hazardous: Without Warning

Hazardous: With Warning

Very High

High

Moderate

Low

Very Low

8/14/2019 Six Sigma Consultants, 1996

10/24

Severity

Page 10

Minor

Very Minor

None

8/14/2019 Six Sigma Consultants, 1996

11/24

Severity

Page 11

Criteria: Severity of Effect DefinedMay endanger operator. Failure mode affects safe vehicle operation and / or involvesnoncompliance with government regulation. Failure will occur WITHOUT warning.

May endanger operator. Failure mode affects safe vehicle operation and / or involvesnoncompliance with government regulation. Failure will occur WITH warning.Major disruption to production line. 100% of product may have to be scrapped. Vehicle / iteminoperable, loss of primary function. Customer very dissatisfied.

Minor disruption to production line. Product may have to be sorted and a portion (less than 100%)scrapped. Vehicle operable, but at a reduced level of performance. Customer dissatisfied.

Minor disruption to production line. A portion (less than 100%) may have to be scrapped (nosorting). Vehicle / item operable, but some comfort / convenience item(s) inoperable. Customersexperience discomfort.

Minor disruption to production line. 100% of product may have to be reworked. Vehicle / itemoperable, but some comfort / convenience item(s) operable at reduced level of performance.Customer experiences some dissatisfaction.

Minor disruption to production line. The product may have to be sorted and a portion (less than100%) reworked. Fit / finish / squeak / rattle item does not conform. Defect noticed by mostcustomers.

8/14/2019 Six Sigma Consultants, 1996

12/24

8/14/2019 Six Sigma Consultants, 1996

13/24

Severity

Page 13

Ranking

10

9

8

7

6

5

4

8/14/2019 Six Sigma Consultants, 1996

14/24

8/14/2019 Six Sigma Consultants, 1996

15/24

Occurance

Page 15

8/14/2019 Six Sigma Consultants, 1996

16/24

Occurance

Page 16

8/14/2019 Six Sigma Consultants, 1996

17/24

Occurance

Page 17

Probability of Failure

Very High:

Failure is almost inevitable

processes that have often failed

previous processes which have

High: Generally associated with processes similar to previous

Moderate: Generally associated with processessimilar to

experienced occasional failures, but not in major proportions

Low: Isolated failures associated with similar processes

Very Low: Only isolated failures associated withalmost identical processes

8/14/2019 Six Sigma Consultants, 1996

18/24

8/14/2019 Six Sigma Consultants, 1996

19/24

Occurance

Page 19

Cpk Ranking

< 0.33 10

1 in 3 9

1 in 8 8

1 in 20 7

1 in 80 6

1 in 400 5

1 in 2,000 4

1 in 15,000 3

1 in 150,000 2

Possible FailureRates

1 in 2

0.33

0.51

0.67

0.83

1.00

1.17

1.33

1.5

8/14/2019 Six Sigma Consultants, 1996

20/24

Occurance

Page 20

1

tial Failure Effects Analysis Third Edition

1 in 1,500,000 1.67

8/14/2019 Six Sigma Consultants, 1996

21/24

Detection

Page 21

8/14/2019 Six Sigma Consultants, 1996

22/24

8/14/2019 Six Sigma Consultants, 1996

23/24

Detection

Page 23

No known control(s) available to detect failure mode

Test content must detect 60 % of failures

Test content must detect 65 % of failuresTest content must detect 70 % of failuresTest content must detect 75 % of failuresTest content must detect 80 % of failuresTest content must detect 85 % of failuresTest content must detect 90 % of failures

Test content must detect 95 % of failuresTest content must detect 99.5 % of failures

-3:Potential Failure Effects Analysis Third Edition

Criteria: Liklihood the existence of a defect will bedetected by test content before product advances to

next or subsequent process

8/14/2019 Six Sigma Consultants, 1996

24/24

Detection

Ranking

10

9

876543

21