FMEA forms

SixSigmaConsultants,1996PFMEANumber:ProcessName:ProcessResponsibility:PreparedBy:AffectedProduct(s):PFMEAKeyDate:PFMEAOriginationDate:PFMEARevisionDate:CoreTeamMembers:PotentialFailureModesandEffectsAnalysis(InformationSheet)PFMEAInformationSheetProcessorProductName:Preparedby:Page____of____Responsible:FMEADate(Orig)______________(Rev)_____________ActionsTakenSEVOCCDETRPNThehighestvalueprocessstepsfromtheC&Ematrix.Inwhatwaysmighttheprocesspotentiallyfailtomeettheprocessrequirementsand/ordesignintent?Whatistheeffectofeachfailuremodeontheoutputsand/orcustomerrequirements?Thecustomercouldbethenextoperation,subsequentoperations,anotherdivisionortheenduser.HowSevereistheeffecttothecusotmer?Howcanthefailureoccur?Describeintermsofsomethingthatcanbecorrectedorcontrolled.Bespecific.Tryidentifythecausesthatdirectlyimpactsthefailuremode,i.e.,rootcauses.Howoftendoesthecauseorfailuremodeoccur?Whataretheexistingcontrolsandprocedures(inspectionandtest)thateitherpreventfailuremodefromoccurringordetectthefailureshoulditoccur?ShouldincludeanSOPnumber.HowwellcanyoudetectcauseorFM?SEVxOCCxDETWhataretheactionsforreducingtheoccurrence,orimprovingdetection,orforidentifyingtherootcauseifitisunknown?ShouldhaveactionsonlyonhighRPN'soreasyfixes.Whoisresponsiblefortherecommendedaction?ListthecompletedactionsthatareincludedintherecalculatedRPN.Includetheimplementationdateforanychanges.Whatisthenewseverity?Whatisthenewprocesscapability?Arethedetectionlimitsimproved?RecomkputeRPNafteractionsarecomplete.000000000000000000000000CurrentProcessControlsDETActionResultsRPNRecommendedAction(s)ResponsibilityandCompletionDateProcessFunctionPotentialFailureModePotentialEffectsofFailureSEVPotentialCause(s)/Mechanism(s)ofFailureOCCProcess/ProductFailureModesandEffectsAnalysis(FMEA)FMEAMasterProcessorProductName:Preparedby:Page____of____Responsible:FMEADate(Orig)______________(Rev)_____________ActionsTakenSEVOCCDETRPNThehighestvalueprocessstepsfromtheC&Ematrix.Inwhatwaysmighttheprocesspotentiallyfailtomeettheprocessrequirementsand/ordesignintent?Whatistheeffectofeachfailuremodeontheoutputsand/orcustomerrequirements?Thecustomercouldbethenextoperation,subsequentoperations,anotherdivisionortheenduser.HowSevereistheeffecttothecusotmer?Howcanthefailureoccur?Describeintermsofsomethingthatcanbecorrectedorcontrolled.Bespecific.Tryidentifythecausesthatdirectlyimpactsthefailuremode,i.e.,rootcauses.Howoftendoesthecauseorfailuremodeoccur?Whataretheexistingcontrolsandprocedures(inspectionandtest)thateitherpreventfailuremodefromoccurringordetectthefailureshoulditoccur?ShouldincludeanSOPnumber.HowwellcanyoudetectcauseorFM?SEVxOCCxDETWhataretheactionsforreducingtheoccurrence,orimprovingdetection,orforidentifyingtherootcauseifitisunknown?ShouldhaveactionsonlyonhighRPN'soreasyfixes.Whoisresponsiblefortherecommendedaction?ListthecompletedactionsthatareincludedintherecalculatedRPN.Includetheimplementationdateforanychanges.Whatisthenewseverity?Whatisthenewprocesscapability?Arethedetectionlimitsimproved?RecomkputeRPNafteractionsarecomplete.000000000000000000000000CurrentProcessControlsDETRPNRecommendedAction(s)ResponsibilityandCompletionDateActionResultsProcessFunctionPotentialFailureModePotentialEffectsofFailureSEVPotentialCause(s)/Mechanism(s)ofFailureOCCProcess/ProductFailureModesandEffectsAnalysis(FMEA)Page3SeverityofEffectRatingMayendangermachineoroperator.Hazardouswithoutwarning10Mayendangermachineoroperator.Hazardouswithwarning9Majordisruptiontoproductionline.Lossofprimaryfunction,100%scrap8Reducedprimaryfunctionperformance.Productrequiressorting,somescrapping7Minordisruptionofproduction.SomeScrap.Lossofsecondaryfunctionperformance6Minordisruptiontoproduciton.100%Rework.Reducedsecondaryfunctionperformance.5MinordefectnoticedbymostcustomersProductrequiressortingandsomereworked.4Fit&Finish/Squeak&Rattleitem.Minordefectnoticedbysomecustomers.3Defectsmaybereworkedon-line.Minordefectnoticedbyobservantcustomers.2NoneNoeffect1ExtremeHighModerateLowLikelihoodofOccurrenceFailureRate1in21in31in81in201in801in4001in2000LowProcessisinstatisticalcontrol.1in15kVeryProcessisinstatisticalcontrol.Onlyisolatedfailuresassociatedwithalmostidenticalprocesses.1in150kRe-moteFailureisunlikely.Noknownfailuresassociatedwithalmostidenticalprocesses.1in1.5MFailureisalmostinevitableProcessisnotinstatisticalcontrol.Similarprocesseshaveexperiencedproblems.Processisinstatisticalcontrolbutwithisolatedfailures.Previousprocesseshaveexperiencedoccasionalfailuresorout-of-controlconditions.VeryHighHighModerateCapability(Cpk)Rating.3310.339.518.677.8361.0051.1741.3331.5021.671LikelihoodthatcontrolwilldetectfailureDPPMVeryNoknowncontrol(s)availabletodetectfailuremode.100,00050,00020,00010,0005,0002,0001,000500200100Theprocessautomaticallydetectsfailure.Controlswillalmostcertainlydetecttheexistenceofafailure.ControlshaveagoodchanceofdetectingtheexistanceofafailureLowModerateHighVeryHighControlshavearemotechanceofdetectingthefailure.ControlsmaydetecttheexistenceofafailureProbabilityRating1in1010