Instructions

FMEA Process Steps

1 For each failure mode, list the possible plant/unit effects assuming protection
devices/logic fail to prevent the failure from "going too far."

2 Rate the Severity of each potential effect. How significant is the impact of the
effect to the customer.

3 List the potential causes of the failure mode including failure of the protection
deviced/logic as a cause. There is not necessarily a 1-to-1 relationship with the
failure effects.

4 Rate the Likelihood of Occurrence of each cause. How likely is the cause of the
failure mode to occur.

5 For each potential cause, list the main method for preventing the cause from
occurring, detecting that the cause has occurred and/or preventing the failure
from continuing to the point that the effects are realized.

6 Rate the Merit of the preventative measures. How well do the preventative
measures prevent or detect a cause and prevent it from continuing to the point
that failure effects will be realized.

7 To calculate the RPN, pick the highest rated effect that is a logical outcome of
each cause (if more than one effect) and multiply that Severity by the Likelihood
of Occurrence and the Merit of Preventative Measures.

8 For any cause the an RPN greater than 120, recommend actions to eliminate
the cause and/or enhance the prevention and detection.

9 Assign responsibility for the recommended actions.

10 Re-evaluate the RPN after actions have been taken.

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 Ratings
Rating Degree of Severity Liklihood of Occurrence Merit
1 Negligible Severity: Customer will not notice the Unlikely that this cause would occur. The cause will be detected and prevented from
adverse effect or it is insignificant. proceeding to the point that the effect is realized.

2 Mild Severity: Customer will probably experience This cause would occur only under rare The cause will be detected and probably will be
slight annoyance with no change in performance. circumstances. prevented from proceeding to the point that the
Repair can be done at time of regular effect is realized.
maintenance.
3 Mild Severity: Customer will experience This cause would occur only under rare The cause probably will be detected and, if
annoyance due to the slight degradation of circumstances. detected, will be prevented from proceeding to
performance. Repair can be done at time of the point that the effect is realized.
regular maintenance.
4 Moderate Severity: Customer dissatisfaction due Occasional occurrences. The cause probably will be detected and, if
to reduced performance. Repair is inexpensive detected, probably will be prevented from
and downtime is short. proceeding to the point that the effect is realized.

5 Moderate Severity: Customer is made Relatively moderate likelihood of occurrence. The cause will be detected but probably will not
uncomfortable by reduced performance or be prevented from proceeding to the point that
appearance degradation. Repair is inexpensive the effect is realized.
and downtime is short.
6 Moderate Severity: Customer dissatisfied due to Moderate likelihood of occurrence. The cause probably will not be detected but, if
intolerable performance degradation or detected, will be prevented from proceeding to
appearance degradation. Repair is inexpensive the point that the effect is realized.
and downtime is short.
7 High Severity: High degree of customer Relatively high likelihood of ocurrence. The cause probably will be detected but, if
dissatisfaction due to component failure without detected, probably will not be prevented from
complete loss of function. Downtime is proceeding to the point that the effect is realized.
expensive. Possible nonconformance to
government regulations.
8 Very High Severity: Very high dissatisfaction due Cause is very likely to occur. The cause probably will not be detected but, if
to the loss of function without a negative impact detected, probably will be prevented from
on safety or governmant regulations. proceeding to the point that the effect is realized.

9 Potential Safety Problems: Customer endangered Cause is almost certain to occur. The cause probably will not be detected and, if
due to the adverse effect on safe system detected, probably will not be prevented from
performance with warning before failure or proceeding to the point that the effect is realized.
violation of government regulations.
10 Potential Safety Problems: Customer endangered Cause is certain to occur. The cause will not be detected and therefore, will
due to the adverse effect on safe system not be prevented from proceeding to the point
performance without warning before failure or that the effect is realized.
violation of government regulations.

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 FMEA - Blank

Process/Product
Failure Modes and Effects Analysis
(FMEA)

Process or
Prepared by: Page ____ of ____
Product Name:

Responsible: FMEA Date (Orig) ______________ (Rev) _____________

M M
E E
S O R R S O R R
Assembly/ Potential Failure Mode Potential Failure Effects of E C In place & Scheduled Cause I P Actions E C I P
Part/Function (Process Condition) Failure on Customer V Potential Causes of Failure C Preventions or Detections T N Recommended Resp. Actions Taken V C T N
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0

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