POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (DESIGN FMEA)

____ System
____ Subsystem FMEA Number:
____ Component _______________________________ Design Responsibility Prepared by:
Model Year(s)/Vehicle(s) Key Date Date (Orig.)
Core Team: Date (Rev.)

Responsibility Action Results

DETECT
OCCUR
Recommended

CLASS

RPN #
Potential Cause(s)/ Current Design Controls Current Design & Target

SEV
Item/ Function Potential Failure Mode Potential Effect(s) of Failure Action(s) and
Mechanism(s) of Failure(s) Prevention Controls Detection Completion

OCC

RPN
SEV

DET
Action Results Actions Taken
Date

Page 1 of 9
SUGGESTED DESIGN FMEA SEVERITY RANKINGS

Severity Effect Criteria: Severity of Effect on Product (Customer Effect) Ranking

Failure to Meet Potential failure mode affects safe vehicle operation and/or involves
10
Safety and/or noncompliance with government regulation without warning
Regulatory Potential failure mode affects safe vehicle operation and/or involves
Requirements 9
noncompliance with government regulation with warning
Loss of primary function (Vehicle inoperable, does not affect safe vehicle
Loss or 8
operation).
Degradation of
Primary Function Degradation of primary function (vehicle operable, but at reduced level of 7
performance).
Loss or Loss of secondary function (vehicle operable, but comfort/convenience
6
Degradation of functions inoperable).
Secondary Degradation of secondary function (vehicle operable, but
Function 5
comfort/convenience functions at reduced level of performance).
Appearance or Audible Noise, vehicle operable, item does not conform and
4
noticed by most customers (>75%).
Appearance or Audible Noise, vehicle operable, item does not conform and
Annoyance 3
noticed by many customers (50%)
Appearance or Audible Noise, vehicle operable, item does not conform and
2
noticed by discriminating customers (<25%).
No effect No discernible effect. 1
SUGGESTED DESIGN FMEA OCCURRENCE RANKINGS

Probability of Failure Likely Failure Rates Likely Failure Rates Ppk Ranking
> 100 per thousand pieces More than one
Very High: Persistent 100,000 ppm or 10% occurrence per day <0.55 10
Failures 50 per thousand pieces One occurrence
50,000 ppm or 5% every 3 to 4 days >0.55 9
20 per thousand pieces One occurrence per
20,000 ppm or 2% week >0.78 8
High: Frequent Failures
10 per thousand pieces One occurrence
10,000 ppm or 1% every month >0.86 7
5 per thousand pieces One occurrence
5,000 ppm or 0.5% every three months >0.94 6
Moderate: Occasional 2 per thousand pieces One occurrence
Failures 2,000 ppm or 0.2% every six months >1.00 5
1 per thousand pieces One occurrence per
1,000 ppm or 0.1% year >1.10 4
1 in 2,000 pieces One occurrence
Low: Relatively Few 500 ppm or 0.05% every 1 to 3 years >1.20 3
Failures 1 in 10,000 pieces One occurrence
100 ppm or 0.01% every 3 to 5 years >1.30 2
1 in 100,000 pieces One occurrence
Remote: Failure is Unlikel 10 ppm or 0.001% greater than 5 years >1.67 1

Note: Likely failure rates are based on internal occurences only, not frequency of defect escapes to
the customer

Note: Same table as PFMEA

SUGGESTED DESIGN FMEA DETECTION RANKINGS

Detection Criteria: Likelihood of Detection by Design Control Ranking

Almost Design Control will not and/or can not detect a potential cause/mechanism and
Impossible subsequent failure mode; or there is no Design Control. 10
Very remote chance the Design Control will detect a potential cause/mechanism
Very Remote and subsequent failure mode. 9
Remote chance the Design Control will detect a potential cause/mechanism and
Remote subsequent failure mode. 8
Very low chance the Design Control will detect a potential cause/mechanism and
Very Low subsequent failure mode 7
Low chance the Design Control will detect a potential cause/mechanism and
Low subsequent failure mode 6
Moderate chance the Design Control will detect a potential cause/mechanism and
Moderate subsequent failure mode 5
Moderately Moderately high chance the Design Control will detect a potential
High cause/mechanism and subsequent failure mode 4
High chance the Design Control will detect a potential cause/mechanism and
High subsequent failure mode 3
Very high chance the Design Control will detect a potential cause/mechanism and
Very High subsequent failure mode 2
Design Control will almost certainly detect a potential cause/mechanism and
Certain subsequent failure mode 1
 POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (DESIGN FMEA)
Responsibility Action Results

DETECT
OCCUR
Recommended

CLASS

RPN #
Potential Cause(s)/ Current Design Controls Current Design & Target

SEV
Item/Function Potential Failure Mode Potential Effect(s) of Failure Action(s) and
Mechanism(s) of Failure(s) Prevention Controls Detection Completion

OCC

RPN
SEV

DET
Action Results Actions Taken
Date

A Functions No function - Component: xxx(7) 7 A - xxxx 5 1 - xxxxx (5) 1 - xxxxx (7) 7 245 1 - xxxxxx xxxxxxx
examples: xxxxx System: xxx(5) B - xxxxx C 2 - xxxx (7) 2 - xxxx (8) 2 - xxxx mm/dd/yy
xxxxxx Adjacent System: xxx(5) - xxxxx 3 - xxx
End User: NA (6 x 4 x 4)
Vehicle: xxx(6)
Regulatory: NA

Partial Function - Component: xxx(7) 7 A - xxxx 4 1 - xxxxx (6) 1 - xxxxx (7) 7 196 1 - xxxxxx xxxxxxx
examples: System: xxx(5) B - xxxxx 2 - xxxx (4) 2 - xxxx (8) 2 - xxx mm/dd/yy
Adjacent System: xxx(5) C - xxxxx (6 x 4 x 4)
End User: NA
Vehicle: xxx(6)
Regulatory:
Intermittent Function - Component: xxx(7) 7 A - xxxx 4 xxxx 1 - xxxxx (7) 7 196 1- xxxxxx xxxxxxx
examples: System: xxx(5) B - xxxxx 2 - xxxx (8) (7 x 4 x 3) mm/dd/yy
Adjacent System: xxx(5) C - xxxxx 3 - xxxxxxx (8)
End User: NA
Vehicle: xxx(6)
Regulatory: NA
Loss of Function Over Component: xxx(6) 6 xxxxxxxxxxx 4 xxxxxxxx 1 - xxxxx (7) 7 168 1- xxxxxx xxxxxxx xxxxxxx 6 4 3 72
Time - examples: System: xxx(5) 2 - xxxx (8) (6 x 4 x 3) mm/dd/yy mm/dd/yy
Adjacent System: xxx(5)
End User: (6) Vehicle:
xxx(6) Regulatory: NA
Unintended Function - Component: xxx(7) 9 <S> xxxxxxxxxxx 5 xxxx xxxxxxx 2 90 1- xxxxxx xxxxxxx xxxxxxx 7 5 2 70
examples: System: xxx(5) (7 x 5 x 2) mm/dd/yy mm/dd/yy
Adjacent System: xxx(5)
End User: NA
Vehicle: xxx(6)
Regulatory: (9)
B Functions
C Functions
A Components
Functions…

B Components
Functions…

A Sub-
Assembly
Functions
B Sub-
Assembly
Functions
C Sub-
Assembly
Functions
 POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (DESIGN FMEA)
Responsibility Action Results

DETECT
OCCUR
Recommended

CLASS

RPN #
Potential Cause(s)/ Current Design Controls Current Design & Target

SEV
Item/Function Potential Failure Mode Potential Effect(s) of Failure Action(s) and
Mechanism(s) of Failure(s) Prevention Controls Detection Completion

OCC

RPN
DET
SEV
Action Results Actions Taken
Date

A. Illuminate a No function – Light No light, customer 8 A - No electrical system 4 A - Spring contact and A & B- Electrical and 2` 64 Design Joey C Completed 10/1/13 8 4 2 64
targeted, dark doesn’t work dissatisfaction continuity electrical design to continuity checks in compartment to 8/4/13
area. Directed ensure continuity even if process and final hold spare bulb
light source. B - Broken bulb not fully assembled inspections.
C -Batteries inserted B - Add a replacement C- Visual checks for
backward bulb polarity marking and
C - Clearly visible and legibility in process and
permanently marked final.
battery polarity on the C - Artwork review and
light approval for packaging
C - Provide clear battery instructions.
insertion and polarity
instructions on the
package instructions

Partial Function – Lower Less light, customer 7 A. Bulb degredation 5 A- Add a replacement A - Electrical and 4 140 Design Joey C Completed 10/1/13 7 4 4 112
level light lumens annoyance or dissatisfaction B- Battery degredation bulb continuity checks in compartment to 8/4/13
B- Bulb selection for process and final hold spare bulb
maximum performance inspections.
from 66% of two AA B- Design validation
batteries (2.0V) testing per LP457

Intermittent Light Flashlight doesn't always 7 A - Misassembly by consumer 3 A & C. Design from A - Electrical and 2 42 None
work when turned on, or (not tightly screwed together) aluminum with fine continuity checks in
stay on consistently. B- machine threads to process and final
Customer annoyance or Intermittent electrical contact improve fit, tolerance, inspections.
dissatisfaction. (bent spring, not enough and ease of assembly C-Life test, abuse test
tension between with assured and design validatiohn
spring/batter/bulb) B - spec spring per testing per LP457
C - Loose fit in the ASTM standard, or better
battery compartment allowing
Loss of Function Over Battery deterioration (wear 6 battery
Nothingand
cancomponent
be done for battery 4 N Design validation 5 120 None
Time item), Bulb deterioration deterioration. testing per LP457,
(wear item). Customer Bulbs are wear items and including drop testing,
annoyance. require periodic replacement. abuse testing and
vibration testing

Unintended Function – Customer injury or death 10 <S> This product is not designed for 1 Warn on packaging - Not None 10 100 None
spark causing explosion around expolsive gases or use in explosive atmospheres. for use in explosive
vapors Gaps in contact points can atmospheres
generate sparks. Design tight
fits and tolerances with spring
force appropriate to avoid air
gaps and sparks.
Bulbs self contained and would
not create external spark or
heat to ignite a gas.
B Functions No function -
examples: xxxxx
xxxxxx
Partial Function -
examples:
Intermittent Function -
examples:
Loss of Function Over
Time - examples:
Unintended Function -
examples:
C Sub- No function -
Assembly examples: xxxxx
Functions xxxxxx
Partial Function -
examples:
Intermittent Function -
examples:
Loss of Function Over
Time - examples:
Unintended Function -
examples:
Flashlight (MAG-LITE) - Design FMEA
What functions are supposed to be performed by the flashlight (features, characteristics)? What is it supposed to do? Regulat

Functions of the flashlight:

1. Illuminate dark areas

2. Emergency lighting
3. Focused lighting
4. Etc.

What are all component parts and subassemblies and their function? Think about mating parts and their function. What dysf

Functions of the components and subassemblies:

1. Battery electrical contacts

2. Battery containment
3. Waterproof sealing / housing
4. Bulb to electrical contacts to battery to on/off switch
5. End cap to seal and secure batteries and contact
6. Etc.
is it supposed to do? Regulatory requirements?

and their function. What dysfunctions and unmarketability can occur? Don’t forget packaging and labeling.