Failure Mode and Effects Analysis - AIAG 4th Edition format (RPN method)
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| # | Process Step / Function | Potential Failure Mode | Potential Effect(s) of Failure | S | Potential Cause(s) | O | Current Controls (Prevention) | Current Controls (Detection) | D | RPN | Recommended Action | Resp. | Target Date |
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Results of actions and rating reference scales
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| # | Action Taken | Date Completed | S | O | D | Revised RPN | Notes |
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Severity (S)
| Rating | Effect |
|---|---|
| 10 | Hazardous without warning |
| 9 | Hazardous with warning |
| 8 | Very high (inoperable, 100% scrap) |
| 7 | High (reduced performance) |
| 6 | Moderate (partial malfunction) |
| 5 | Low (reduced performance, noticed) |
| 4 | Very low (minor, noticed by most) |
| 3 | Minor (noticed by some) |
| 2 | Very minor (noticed by few) |
| 1 | None (no discernible effect) |
Occurrence (O)
| Rating | Probability |
|---|---|
| 10 | Very high (≥ 1 in 2) |
| 9 | Very high (1 in 3) |
| 8 | High (1 in 8) |
| 7 | High (1 in 20) |
| 6 | Moderate (1 in 80) |
| 5 | Moderate (1 in 400) |
| 4 | Moderate (1 in 2,000) |
| 3 | Low (1 in 15,000) |
| 2 | Low (1 in 150,000) |
| 1 | Remote (≤ 1 in 1,500,000) |
Detection (D)
| Rating | Likelihood of Detection |
|---|---|
| 10 | Almost impossible to detect |
| 9 | Very remote |
| 8 | Remote |
| 7 | Very low |
| 6 | Low |
| 5 | Moderate |
| 4 | Moderately high |
| 3 | High |
| 2 | Very high |
| 1 | Almost certain to detect |
This FMEA worksheet has been prepared in accordance with the AIAG FMEA Reference Manual 4th Edition methodology. All failure modes have been assessed by the cross-functional team listed above. Recommended actions have been assigned with responsible persons and target completion dates. This document should be reviewed and updated whenever the process, design or controls change.